Yamaha XV535

Download as pdf or txt
Download as pdf or txt
You are on page 1of 87

OWNER’S MANUAL

XV535
3BT-28199-E6
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/INT.frame

INTRODUCTION

EAU00001

Welcome to the Yamaha world of motorcycling!

As the owner of a XV535, you are benefiting from YamahaÕs vast experience in and
newest technology for the design and the manufacture of high-quality products, which
have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all your XV535Õs ad-
vantages. The ownerÕs manual does not only instruct you in how to operate, inspect
and maintain your motorcycle, but also in how to safeguard yourself and others from
trouble and injury.

In addition, the many tips given in this manual will help to keep your motorcycle in the
best possible condition. If you have any further questions, do not hesitate to contact
your Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to put
safety first!
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/INT.frame

IMPORTANT MANUAL INFORMATION


EAU00005

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to


the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

l This manual should be considered a permanent part of this motorcycle and should remain with it
even if the motorcycle is subsequently sold.
l Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there may
be minor discrepancies between your motorcycle and this manual. If there is any question con-
cerning this manual, please consult your Yamaha dealer.
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/INT.frame

IMPORTANT MANUAL INFORMATION


EW000002

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS
MOTORCYCLE.
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/INT.frame

EAU00008

XV535
OWNERÕS MANUAL
©1999 by Yamaha Motor Co., Ltd.
1st Edition, April 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-TOC.frame

EAA30002

TABLE OF CONTENTS

1 GIVE SAFETY THE RIGHT OF WAY

2 DESCRIPTION

3 INSTRUMENT AND CONTROL FUNCTIONS

4 PRE-OPERATION CHECKS

5 OPERATION AND IMPORTANT RIDING POINTS

6 PERIODIC MAINTENANCE AND MINOR REPAIR

7 MOTORCYCLE CARE AND STORAGE

8 SPECIFICATIONS

9 CONSUMER INFORMATION

INDEX
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-TOC.frame
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-1TOC.frame

GIVE SAFETY THE RIGHT OF WAY

GIVE SAFETY THE RIGHT OF WAY................................................. 1-1


L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-1.frame

GIVE SAFETY THE RIGHT OF WAY EAU00021

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom.
However, they also impose certain limits, which you must accept; even the best motorcycle does not ig-
nore the laws of physics.

Regular care and maintenance are essential for preserving your motorcycleÕs value and operating condi-
tion. Moreover, what is true for the motorcycle is also true for the rider: good performance depends on be-
ing in good shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the
question. Motorcycle riders Ð more than car drivers Ð must always be at their mental and physical best.
Under the influence of even small amounts of alcohol, there is a tendency to take dangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers.
Always wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials
with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear,
however, should not encourage carelessness. Though full-coverage helmets and suits, in particular, cre-
ate an illusion of total safety and protection, motorcyclists will always be vulnerable. Riders who lack criti-
cal self-control run the risk of going too fast and are apt to take chances. This is even more dangerous in
wet weather. The good motorcyclist rides safely, predictably and defensively Ð avoiding all dangers, in-
cluding those caused by others.

Enjoy your ride!

1-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-2TOC.frame

DESCRIPTION

Left view ............................................................................................. 2-1


Right view........................................................................................... 2-2
Controls/Instruments .......................................................................... 2-3
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-2.frame

DESCRIPTION EAU00026

Left view

1. Headlight (page 6-27) 6. Rear shock absorber spring


2. Air filter (page 6-10) preload adjusting ring (page 3-9)
3. Rider seat (page 3-7) 7. Main switch (page 3-1)
4. Tool kit (page 6-1) 8. Starter (choke) Ò Ó (page 3-6)
5. Passenger seat (page 3-7) 9. Shift pedal (page 3-4)
2-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-2.frame

DESCRIPTION

Right view

10. Rear turn signal light (page 6-29) 13. Front turn signal light (page 6-29)
11. Sub fuel tank 14. Rear brake pedal (page 3-4)
12. Fuel tank (page 3-5) 15. Battery (page 6-25)

2-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-2.frame

DESCRIPTION

Controls/Instruments

1. Clutch lever (page 3-3)


2. Speedometer (page 3-2)
3. Front brake lever (page 3-4)
4. Throttle grip (page 6-13)
5. Right handlebar switches (page 3-3)
6. Left handlebar switches (page 3-2)

2-3
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3TOC.frame

INSTRUMENT AND CONTROL FUNCTIONS

Main switch ........................................................................................ 3-1


Indicator lights .................................................................................... 3-1
Speedometer...................................................................................... 3-2
Handlebar switches............................................................................ 3-2
Clutch lever ........................................................................................ 3-3
Shift pedal .......................................................................................... 3-4
Front brake lever ................................................................................ 3-4
Rear brake pedal................................................................................ 3-4
Fuel tank cap...................................................................................... 3-5
Fuel .................................................................................................... 3-5
Starter (choke) Ò Ó........................................................................... 3-6
Steering lock ...................................................................................... 3-6
Seats .................................................................................................. 3-7
Helmet holder..................................................................................... 3-8
Rear shock absorber adjustment ....................................................... 3-9
Sidestand ........................................................................................... 3-9
Sidestand/clutch switch operation check ......................................... 3-10
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS EAU00027

EAU00028 1. Push 1. High beam indicator light Ò Ó


Main switch 2. Release 2. Neutral indicator light Ò Ó
The main switch controls the ignition 3. Turn 3. Turn indicator light Ò Ó

and lighting systems. Its operation is EAU00055 EAU00056

described below.
P (Parking) Indicator lights
The taillight and auxiliary light come on EAU00063

EAU00036 but all other circuits are off. With the High beam indicator light Ò Ó
ON key at ÒOFFÓ, push it into the main This indicator comes on when the
Electrical circuits are switched on. The switch and release it. Then turn it coun- headlight high beam is used.
engine can be started. The key cannot terclockwise to ÒPÓ, and remove it. (Do
EAU00061
be removed in this position. not use this position for an extended Neutral indicator light Ò Ó
length of time as the battery may dis- This indicator comes on when the
EAU00038
charge.) To cancel the parking, turn the transmission is in neutral.
OFF
key clockwise.
All electrical circuits are switched off. EAU00057

The key can be removed in this posi- Turn indicator light Ò Ó


tion. This indicator flashes when the turn
switch is moved to the left or right.

3-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS


EAU00124

Turn signal switch Ò Ó


This model is equipped with self-can-
celling turn signals. To signal a right-
hand turn, push the switch to the right.
To signal a left-hand turn, push the
switch to the left. Once the switch is re-
leased it will return to the center posi-
tion. To cancel the signal, push the
1. Reset knob 1. Pass switch Ò Ó switch in after it has returned to the
2. Odometer 2. Dimmer switch center position. If the switch is not can-
3. Trip odometer 3. Turn signal switch Ò Ó celled by hand, it will self-cancel after
4. Horn switch Ò Ó
EAU00095
the motorcycle has travelled at least
Speedometer EAU00118
150 meters and 15 seconds have
The speedometer shows riding speed. Handlebar switches
passed. The self-cancelling mecha-
This speedometer is equipped with an nism only operates when the motor-
EAU00119
odometer and trip odometer. The trip Pass switch Ò Ó cycle is moving. Therefore the signal
odometer can be reset to Ò0Ó with the Press the switch to operate the passing will not self-cancel while you are
reset knob. Use the trip odometer to light. stopped at an intersection.
estimate how far you can ride on a tank
of fuel. This information will enable you EAU00121 EAU00129

to plan fuel stops in the future. Dimmer switch Horn switch Ò Ó


Turn the switch to Ò Ó for the high Press the switch to sound the horn.
beam and to Ò Ó for the low beam.

3-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS


EAU00143

Start switch Ò Ó
The starter motor cranks the engine
when pushing the start switch.
EC000005

CAUTION:
See starting instructions prior to
starting the engine.

1. Engine stop switch 1. Clutch lever


EAU00149
2. Lights switch
3. Start switch Ò Ó
Fuel reserve switch ÒFUELÓ EAU00152

4. Fuel reserve switch ÒFUELÓ This switch should usually be kept Clutch lever
EAU00138 ÒONÓ while riding. If you run out of fuel The clutch lever is located on the left
Engine stop switch while riding, move the switch to ÒRESÓ handlebar, and the ignition circuit cut-
The engine stop switch is a safety de- and refuel at the first opportunity. Then off system is incorporated in the clutch
vice for use in an emergency such as move the switch to ÒONÓ. lever holder. Pull the clutch lever to the
when the motorcycle overturns or if handlebar to disengage the clutch, and
trouble occurs in the throttle system. release the lever to engage the clutch.
Turn the switch to Ò Ó to start the en- When the switch is turned to reserve The lever should be pulled rapidly and
gine. In case of emergency, turn the ÒRESÓ, about 2.5 L remain in the fuel released slowly for smooth clutch oper-
switch to Ò Ó to stop the engine. tank. ation. (Refer to the engine starting pro-
EAU00134
cedures for a description of the ignition
Lights switch circuit cut-off system.)
Turning the light switch to Ò Ó,
turns on the auxiliary light, meter lights
and taillight. Turning the light switch to
Ò Ó, turns the headlight on also.
3-3
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS

1. Shift pedal 1. Front brake lever 1. Rear brake pedal


EAU00157 EAU00158 EAU00162

Shift pedal Front brake lever Rear brake pedal


This motorcycle is equipped with a con- The front brake lever is located on the The rear brake pedal is on the right
stant-mesh 5-speed transmission. right handlebar. Pull it toward the han- side of the motorcycle. Press down on
The shift pedal is located on the left dlebar to apply the front brake. the brake pedal to apply the rear brake.
side of the engine and is used in com-
bination with the clutch when shifting.

3-4
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS


NOTE:
This tank cap cannot be closed unless
the key is in the lock. The key cannot
be removed if the cap is not locked
properly.
EW000023

Be sure the cap is properly installed


1. Open 1. Filler tube
and locked in place before riding the 2. Fuel level
EAU00167
motorcycle.
Fuel tank cap EAU01183

To open Fuel
Insert the key and turn it 1/4 turn clock- Make sure there is sufficient fuel in the
wise. The lock will be released and the tank. Fill the fuel tank to the bottom of
cap can be opened. the filler tube as shown in the illustra-
tion.
EW000130
To close
Push the tank cap into position with the
key inserted. To remove the key, turn it Do not overfill the fuel tank. Avoid
counterclockwise to the original posi- spilling fuel on the hot engine. Do
tion. not fill the fuel tank above the bot-
tom of the filler tube or it may over-
flow when the fuel heats up later and
expands.

3-5
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS


EAU00185

CAUTION:
Always wipe off spilled fuel immedi-
ately with a dry and clean soft cloth.
Fuel may deteriorate painted surfac-
es or plastic parts.

EAU00191

1. Starter (choke) Ò Ó 1. Steering lock


Recommended fuel:
EAU02976 EAU02934
Regular unleaded gasoline with
Starter (choke) Ò Ó Steering lock
a research octane number of 91
Starting a cold engine requires a richer To lock the steering
or higher.
air-fuel mixture. A separate starter cir- Turn the handlebars all the way to the
Fuel tank capacity:
cuit supplies this mixture. right and open the steering lock cover.
Total:
Move in direction a to turn on the Insert the key and turn it 1/8 turn coun-
13.5 L
starter (choke). terclockwise. Then, push the key in
Reserve:
Move in direction b to turn off the while turning the handlebars slightly to
2.5 L
starter (choke). the left and turn the key 1/8 turn clock-
wise.
NOTE: Check that the steering is locked, re-
If knocking or pinging occurs, use a dif- move the key and close the lock cover.
ferent brand of gasoline or higher oc-
tane grade. To unlock the steering
Insert the key, push it in and turn it 1/8
turn counterclockwise so that it moves
out. Then, release and remove the key.
3-6
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS

1. Seat lock 1. Projection 1. Bolt (´ 2)


2. Open 2. Seat holder
Rider seat
EAU02940
To install To remove
Seats Insert the projection on the rear of the Remove the passenger seat and then
Passenger seat seat into the seat holder, and then push remove the two rider seat bolts.
To remove down on the seat.
Insert the key in the seat lock and turn it
clockwise.

3-7
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS

1. Seat holder (´ 2) 1. Open


2. Projection (´ 2) EAU00260

To install Helmet holder


Insert the projections on the front of the To open the helmet holder, insert the
seat into the seat holders and tighten key in the lock and turn it as shown. To
the bolts. Then, install the passenger lock the helmet holder, replace the
seat. holder in its original position.
EW000030

Make sure that the seats are securely


Never ride with a helmet in the hel-
fitted.
met holder. The helmet may hit ob-
jects, causing loss of control and
possibly an accident.

3-8
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS


EAU00330

Soft Standard Hard Sidestand


Adjusting
1 2 3 4 5 This model is equipped with an ignition
position
circuit cut-off system. The motorcycle
EW000040 must not be ridden when the sidestand
is down. The sidestand is located on
the left side of the frame. (Refer to
Always adjust each shock absorber
page 5-1 for an explanation of this sys-
to the same setting. Uneven adjust-
tem.)
ment can cause poor handling and EW000044
1. Spring preload adjusting ring loss of stability.
2. Position indicator
EAU00300 This motorcycle must not be operat-
Rear shock absorber ed with the sidestand in the down
adjustment position. If the stand is not properly
Each shock absorber is equipped with retracted, it could contact the
a spring preload adjusting ring. Adjust ground and distract the operator, re-
spring preload as follows. Turn the ad- sulting in a possible loss of control.
justing ring in direction a to increase Yamaha has designed into this mo-
spring preload and in direction b to de- torcycle a lockout system to assist
crease spring preload. Make sure that the operator in fulfilling the respon-
the appropriate notch in the adjusting sibility of retracting the sidestand.
ring is aligned with the position indica- Please check carefully the operating
tor on the rear shock absorber. instructions listed below and if there
is any indication of a malfunction,
return the motorcycle to a Yamaha
dealer immediately for repair.

3-9
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame

INSTRUMENT AND CONTROL FUNCTIONS


EAU00331

Sidestand/clutch switch SIDESTAND IS DOWN.


operation check
Check the operation of the sidestand
ENGINE WILL STALL.
switch and clutch switch against the in-
formation below.
SIDESTAND SWITCH IS OK.
TURN THE MAIN SWITCH TO ÒONÓ
EW000045
AND THE ENGINE STOP SWITCH TO
Ò Ó.
If improper operation is noted, con-
sult a Yamaha dealer immediately.
TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP.

PULL IN CLUTCH LEVER AND


PUSH THE START SWITCH.

ENGINE WILL START.

CLUTCH SWITCH IS OK.

3-10
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-4TOC.frame

PRE-OPERATION CHECKS

Pre-operation check list...................................................................... 4-1


L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-4.frame

PRE-OPERATION CHECKS EAU01114

Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340

PRE-OPERATION CHECK LIST


ITEM CHECKS PAGE
¥ Check operation, free play, fluid level and vehicle for fluid leakage.
Front brake
¥ Fill with DOT 4 (or DOT 3) brake fluid if necessary.
6-17 ~ 6-21
¥ Check operation, condition and free play.
Rear brake
¥ Adjust if necessary.
¥ Check operation, condition and free play.
Clutch 6-17
¥ Adjust if necessary.
¥ Check for smooth operation.
Throttle grip and housing 6-13
¥ Lubricate if necessary.
¥ Check oil level.
Engine oil 6-7 ~ 6-9
¥ Fill with oil if necessary.
Final gear oil ¥ Check vehicle for leakage. 6-9 ~ 6-10
¥ Check tire pressure, wear, damage and spoke tightness.
Wheels and tires 6-14 ~ 6-16
¥ Tighten spokes if necessary.
¥ Check for smooth operation.
Control and meter cables 6-21
¥ Lubricate if necessary.
Brake and shift pedal ¥ Check for smooth operation.
6-22
shafts ¥ Lubricate if necessary.
Brake and clutch lever ¥ Check for smooth operation.
6-22
pivots ¥ Lubricate if necessary.

4-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-4.frame

PRE-OPERATION CHECKS

ITEM CHECKS PAGE


¥ Check for smooth operation.
Sidestand pivot 6-23
¥ Lubricate if necessary.
¥ Make sure that all nuts, bolts and screws are properly tightened.
Chassis fasteners Ñ
¥ Tighten if necessary.
¥ Check fuel level.
Fuel tank 3-5 ~ 3-6
¥ Fill with fuel if necessary.
Lights, signals and
¥ Check for proper operation. 6-27 ~ 6-29
switches
¥ Check fluid level.
Battery 6-25 ~ 6-26
¥ Fill with distilled water if necessary.

NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom-
plished in a very short time; and the added safety it assures is more than worth the time involved.

If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operating
the motorcycle.

4-2
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-4.frame
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5TOC.frame

OPERATION AND IMPORTANT RIDING POINTS

Starting the engine ............................................................................. 5-1


Starting a warm engine ...................................................................... 5-3
Shifting ............................................................................................... 5-4
Recommended shift points (for Switzerland only).............................. 5-4
Tips for reducing fuel consumption .................................................... 5-5
Engine break-in .................................................................................. 5-5
Parking ............................................................................................... 5-6
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5.frame

OPERATION AND IMPORTANT RIDING POINTS EAU00372

EAU00373 EAU02997

Starting the engine


l Before riding this motorcycle, NOTE:
become thoroughly familiar This motorcycle is equipped with an ig-
with all operating controls and nition circuit cut-off system. The engine
their functions. Consult a can be started only under one of the
Yamaha dealer regarding any following conditions:
control or function that you do l The transmission is in neutral.
not thoroughly understand. l The sidestand is up, the transmis-
l Never start your engine or let it sion is in gear and the clutch is dis-
run for any length of time in a engaged.
closed area. The exhaust fumes The motorcycle must not be ridden
are poisonous and can cause when the sidestand is down.
loss of consciousness and
death within a short time. Al- EW000054

ways operate your motorcycle


in an area with adequate ventila- Before going through the following
tion. steps, check the function of the
l Before starting out, always be sidestand switch and clutch switch.
sure the sidestand is up. Failure (Refer to page 3-10.)
to retract the sidestand com-
pletely can result in a serious
accident when you try to turn a
corner.

5-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5.frame

OPERATION AND IMPORTANT RIDING POINTS

TURN THE MAIN SWITCH TO ÒONÓ AND THE


ENGINE STOP SWITCH TO Ò Ó.

IF THE TRANSMISSION IS IN NEUTRAL IF THE TRANSMISSION IS IN GEAR


AND THE SIDESTAND IS DOWN, AND THE SIDESTAND IS UP,

PUSH THE START SWITCH. PULL IN THE CLUTCH LEVER AND PUSH START
ENGINE WILL START. THE SWITCH. ENGINE WILL START.

RETRACT THE SIDESTAND AND PUT


THE TRANSMISSION IN GEAR.

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.

5-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5.frame

OPERATION AND IMPORTANT RIDING POINTS


EAU01258

1. Turn the main switch to ÒONÓ and 5. After starting the engine, move the Starting a warm engine
the engine stop switch to Ò Ó. starter (choke) to the halfway posi- The starter (choke) is not required
2. Shift the transmission into neutral. tion. when the engine is warm.
EC000046
NOTE: NOTE:
CAUTION:
When the transmission is in neutral, the For maximum engine life, never accel-
neutral indicator light should be on. If erate hard with a cold engine! See the ÒEngine break-inÓ section
the light does not come on, ask a prior to operating the motorcycle for
Yamaha dealer to inspect it. 6. After the engine is warm, turn off the first time.
the starter (choke) completely.
3. Turn on the starter (choke) and
NOTE:
completely close the throttle grip.
The engine is warm when it responds
4. Start the engine by pushing the
normally to the throttle with the starter
start switch.
(choke) turned off.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one attempt.

5-3
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5.frame

OPERATION AND IMPORTANT RIDING POINTS


EC000048 EAU02941

CAUTION: Recommended shift points


l Do not coast for long periods
(for Switzerland only)
with the engine off, and do not The recommended shift points are
tow the motorcycle a long dis- shown in the table below.
tance. Even with gears in neu- Acceleration shift point
tral, the transmission is only (km/h)
properly lubricated when the 1st ® 2nd 23
2nd ® 3rd 36
engine is running. Inadequate 3rd ® 4th 50
1. Shift pedal
N. Neutral
lubrication may damage the 4th ® 5th 60

EAU00423
transmission.
Shifting l Always use the clutch when NOTE:
The transmission lets you control the changing gears. The engine, When shifting two gears down from 4th
amount of power you have available at transmission, and driveline are to 2nd, bring your motorcycle to a
a given speed for starting, accelerating, not designed to withstand the speed of 35 km/h.
climbing hills, etc. The use of the shift shock of forced shifting and
pedal is shown in the illustration. can be damaged by shifting
To shift into neutral, depress the shift without using the clutch.
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.

5-4
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5.frame

OPERATION AND IMPORTANT RIDING POINTS


EAU00424 EAU00436 EAU00444

Tips for reducing fuel Engine break-in 0 ~ 150 km


consumption There is never a more important period Avoid operation above 1/3 throttle.
Your motorcycleÕs fuel consumption in the life of your motorcycle than the Stop the engine and let it cool for 5 to
depends to a large extent on your period between zero and 1,000 km. For 10 minutes after every hour of opera-
riding style. The following tips can help this reason we ask that you carefully tion. Vary the speed of the motorcycle
reduce fuel consumption: read the following material. Because from time to time. Do not operate it at
l Warm up the engine before riding. the engine is brand new, you must not one set throttle position.
l Turn off the starter (choke) as put an excessive load on it for the first
soon as possible. 1,000 km. The various parts in the en- 150 ~ 500 km
l Shift up swiftly and avoid high en- gine wear and polish themselves to the Avoid prolonged operation above
gine speeds during acceleration. correct operating clearances. During 1/2 throttle. Rev the motorcycle freely
l Do not double-clutch or rev the en- this period, prolonged full throttle oper- through the gears, but do not use full
gine while shifting down and avoid ation, or any condition which might re- throttle at any time.
high engine speeds with no load sult in excessive heating of the engine,
on the engine. must be avoided. 500 ~ 1,000 km
l Turn off the engine instead of let- Avoid cruising speeds in excess of
ting it idle for an extended length 3/4 throttle.
EC000056
of time, i.e. in traffic jams, at traffic
CAUTION:
lights or railroad crossings.
After 1,000 km of operation, be sure
to replace the engine oil, oil filter
and final gear oil.

5-5
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5.frame

OPERATION AND IMPORTANT RIDING POINTS


EAU00460

1,000 km and beyond Parking


Avoid prolonged full-throttle operation. When parking the motorcycle, stop the
Vary speed occasionally. engine and remove the ignition key.
EC000049 EW000058

CAUTION:
If any engine trouble should occur The exhaust system is hot. Park the
during the break-in period, consult a motorcycle in a place where pedes-
Yamaha dealer immediately. trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft
ground; the motorcycle may over-
turn.

5-6
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-5.frame
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6TOC.frame

PERIODIC MAINTENANCE AND MINOR REPAIR

Tool kit ................................................................ 6-1 Inspecting the brake fluid level..........................6-20


Periodic maintenance and lubrication................. 6-2 Brake fluid replacement ....................................6-21
Spark plugs ........................................................ 6-5 Cable inspection and lubrication .......................6-21
Engine oil............................................................ 6-7 Throttle cable and grip lubrication.....................6-22
Final gear oil ....................................................... 6-9 Brake and shift pedal lubrication.......................6-22
Air filter ............................................................. 6-10 Brake and clutch lever lubrication .....................6-22
Carburetor adjustment...................................... 6-12 Sidestand lubrication.........................................6-23
Idle speed adjustment ...................................... 6-13 Rear suspension lubrication..............................6-23
Throttle cable free play inspection.................... 6-13 Front fork inspection .........................................6-23
Valve clearance adjustment ............................. 6-14 Steering inspection ...........................................6-24
Tires ................................................................. 6-14 Wheel bearings .................................................6-24
Wheels ............................................................. 6-16 Battery...............................................................6-25
Clutch lever free play adjustment ..................... 6-17 Fuse replacement .............................................6-27
Front brake lever free play adjustment ............. 6-17 Headlight bulb replacement ..............................6-27
Rear brake pedal height and free play Turn signal and taillight bulb replacement ........6-29
adjustment...................................................... 6-18 Troubleshooting ................................................6-29
Brake light switch adjustment ........................... 6-19 Troubleshooting chart .......................................6-30
Checking the front brake pads and
rear brake shoes ............................................ 6-19
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462

EAU00464

Periodic inspection, adjustment and lu- NOTE:


brication will keep your motorcycle in If you do not have necessary tools re-
the safest and most efficient condition quired during a service operation, take
possible. Safety is an obligation of the your motorcycle to a Yamaha dealer
motorcycle owner. The maintenance for service.
and lubrication schedule chart should
EW000063
be considered strictly as a guide to
general maintenance and lubrication
intervals. YOU MUST TAKE INTO Modifications to this motorcycle not
1. Tool kit
CONSIDERATION THAT WEATHER, approved by Yamaha may cause
EAU00469
loss of performance, and render it
TERRAIN, GEOGRAPHICAL LOCA- Tool kit
TIONS, AND A VARIETY OF INDIVID- unsafe for use. Consult a Yamaha
The service information included in this
UAL USES ALL TEND TO DEMAND dealer before attempting any chang-
manual is intended to provide you, the
THAT EACH OWNER ALTER THIS es.
owner, with the necessary information
TIME SCHEDULE TO SHORTER IN- for completing some of your own pre-
TERVALS TO MATCH THE ENVI- ventive maintenance and minor re-
RONMENT. The most important points pairs. The tools provided in the ownerÕs
of motorcycle inspection, adjustment, tool kit are to assist you in the perfor-
and lubrication are explained in the fol- mance of periodic maintenance. How-
lowing pages. ever, some other tools such as a torque
EW000060
wrench are also necessary to perform
the maintenance correctly.
If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.

6-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00473

PERIODIC MAINTENANCE AND LUBRICATION


EVERY
6,000 km 12,000 km
NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL or or
(1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
¥ Check fuel hoses and vacuum hose for cracks or damage.
1 * Fuel line Ö Ö
¥ Replace if necessary.
¥ Check condition.
2 Spark plugs Ö Ö Ö
¥ Clean, regap or replace if necessary.
¥ Check condition.
3 * Fuel filter Ö
¥ Replace if necessary.
¥ Check valve clearance.
4 * Valves Ö Ö Ö
¥ Adjust if necessary.
5 Air filter ¥ Clean or replace if necessary. Ö Ö
¥ Check electrolyte level and specific gravity.
6 * Battery ¥ Correct or recharge if necessary. Ö Ö
¥ Make sure that the breather hose is properly routed.
¥ Check operation.
7 Clutch Ö Ö Ö
¥ Adjust or replace cable.
¥ Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
8 * Front brake Ö Ö Ö
¥ Correct accordingly.
¥ Replace brake pads if necessary.
¥ Check operation.
9 * Rear brake Ö Ö Ö
¥ Adjust brake pedal free play and replace brake shoes if necessary.
¥ Check balance, runout, spoke tightness and for damage.
10 * Wheels Ö Ö
¥ Tighten spokes and rebalance, replace if necessary.

6-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
¥ Check tread depth and for damage.
¥ Replace if necessary.
11 * Tires Ö Ö
¥ Check air pressure.
¥ Correct if necessary.
¥ Check bearing for looseness or damage.
12 * Wheel bearings Ö Ö
¥ Replace if necessary.
¥ Check swingarm pivoting point for play.
13 * Swingarm ¥ Correct if necessary. Ö Ö
¥ Lubricate with molybdenum disulfide grease.
¥ Check bearing play and steering for roughness.
¥ Correct accordingly.
14 * Steering bearings Ö Ö
¥ Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).
¥ Make sure that all nuts, bolts and screws are properly tightened.
15 * Chassis fasteners Ö Ö
¥ Tighten if necessary.
¥ Check operation.
16 Sidestand Ö Ö
¥ Lubricate and repair if necessary.
¥ Check operation.
17 * Sidestand switch Ö Ö Ö
¥ Replace if necessary.
¥ Check operation and for oil leakage.
18 * Front fork Ö Ö
¥ Correct accordingly.
Rear shock absorber ¥ Check operation and shock absorbers for oil leakage.
19 * Ö Ö
assemblies ¥ Replace shock absorber assembly if necessary.
¥ Check engine idling speed, synchronization and starter operation.
20 * Carburetors Ö Ö Ö
¥ Adjust if necessary.
¥ Check oil level and vehicle for oil leakage.
21 Engine oil ¥ Correct if necessary. Ö Ö Ö
¥ Change. (Warm engine before draining.)
6-3
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EVERY
6,000 km 12,000 km
INITIAL or or
NO. ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months
(whichever (whichever
comes first) comes first)
22 Engine oil filter element ¥ Replace. Ö Ö
¥ Check oil level and vehicle for oil leakage.
23 Final gear oil ¥ Change oil at initial 1,000 km and thereafter every 24,000 km Ö Ö Ö
or 24 months (whichever comes first).
* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.

EAU02970

NOTE:
l The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l Hydraulic brake system
¥ When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly
and fill as required.
¥ Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
¥ Replace the brake hoses every four years or if cracked or damaged.

6-4
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


ent color, there could be something
wrong with the engine. Do not attempt
1 to diagnose such problems yourself. In-
1 stead, take the motorcycle to a
Yamaha dealer. You should periodical-
2 ly remove and inspect the spark plugs
because heat and deposits will cause
any spark plug to slowly break down
1. Cylinder head cover 1. Spark plug wrench and erode. If electrode erosion be-
2. Screw (´ 2) comes excessive, or if carbon and oth-
3. Use the spark plug wrench in the
EAU01486 er deposits are excessive, you should
tool kit to remove the spark plugs
Spark plugs replace the spark plug with the speci-
as shown.
Removal fied plug.
1. Remove the rear right and front
Inspection Specified spark plug:
left cylinder head covers by re-
The spark plug is an important engine For CH:
moving the screws.
component and is easy to inspect. The BPR7ES (NGK) or
2. Remove the spark plug caps.
condition of the spark plug can indicate W22EPR-U (DENSO)
the condition of the engine. Normally, Except for CH:
all spark plugs from the same engine BPR6ES (NGK) or
should have the same color on the W20EPR-U (DENSO)
white insulator around the center elec-
trode. The ideal color at this point is a
medium-to-light tan color for a motor-
cycle that is being ridden normally. If
one spark plug shows a distinctly differ-

6-5
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR

Tightening torque:
Spark plug:
20 Nm (2.0 mákg)

NOTE:
If a torque wrench is not available when
you are installing a spark plug, a good
estimate of the correct torque is 1/4 to
a. Spark plug gap 1/2 turn past finger tight. Have the
spark plug tightened to the specified
Installation
torque as soon as possible.
1. Measure the electrode gap with a
wire thickness gauge and, if nec- 4. Install the spark plug caps, the cyl-
essary, adjust the gap to specifica- inder head covers and the screws.
tion.

Spark plug gap:


0.7 ~ 0.8 mm

2. Clean the gasket surface. Wipe off


any grime from the threads.
3. Install the spark plug and tighten it
to the specified torque.

6-6
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the left side crankcase cover.
NOTE:
Wait a few minutes until the oil level
settles before checking.

1. Oil level window 3. The oil level should be between 1. Engine oil filler cap
2. Maximum level mark the maximum and minimum
3. Minimum level mark Engine oil and oil filter element
marks. If the level is low, fill the en-
replacement
EAU02942
gine with sufficient oil to the speci-
Engine oil 1. Warm up the engine for a few min-
fied level.
Oil level inspection utes.
1. Place the motorcycle on a level 2. Stop the engine. Place an oil pan
place and hold it in an upright posi- under the engine and remove the
tion. Warm up the engine for sev- oil filler cap.
eral minutes.
NOTE:
Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings.

6-7
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Engine oil drain bolt 1. Oil filter cover 1. O-ring


2. Bolt (´ 3) 2. Oil filter element
3. Remove the drain bolt and drain
the oil. 4. Remove the oil filter bolts, oil filter NOTE:
and O-ring. Make sure the O-ring is seated proper-
5. Install the drain bolt and tighten it ly.
to the specified torque.
7. Fill the engine with oil. Install the
Tightening torque: oil filler cap and tighten it.
Drain bolt:
43 Nm (4.3 mákg) Recommended oil:
See page 8-1.
6. Install the new oil filter, new O-ring Oil quantity:
and the filter cover. Then tighten the Total amount:
oil filter bolts to the specified torque. 3.2 L
Periodic oil change:
Tightening torque: 2.6 L
Oil filter bolts: With oil filter replacement:
10 Nm (1.0 mákg) 2.8 L

6-8
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EC000066

CAUTION: 2. Remove the oil filler bolt and


check the oil level. The oil level
l Do not put in any chemical addi- should be at the brim of the filler
tives. Engine oil also lubricates hole. Add the recommended oil if
the clutch and additives could necessary.
cause clutch slippage.
l Be sure no foreign material en- Oil replacement
ters the crankcase. 1. Place an oil pan under the final
8. Start the engine and warm it up for 1. Final gear oil drain bolt gear case.
a few minutes. While warming up, 2. Final gear oil 2. Remove the oil filler bolt and drain
3. Final gear oil filler bolt bolt to drain the oil.
check for oil leakage. If oil leakage 4. Correct level
is found, stop the engine immedi- 3. Install and tighten the drain bolt to
EAU02943
the specified torque.
ately and check for the cause. Final gear oil
EW000066
Tightening torque:
Drain bolt:
Do not let foreign material enter the 23 Nm (2.3 mákg)
final gear case. Be sure oil does not
get on the tire or wheel. 4. Fill the gear case to the brim of the
filler hole with the recommended
Oil level inspection oil.
1. Place the motorcycle on a level
place and hold it in an upright posi-
tion. The engine should be cool at
ambient temperature.

6-9
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR

Final gear case capacity:


0.19 L
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid
gear oil may be used for all
conditions.

NOTE: 1. Fuel tank 1. Screw


ÒGL-4Ó is a quality and additive rating. 2. Bolt (´ 3)
3. Lift the front of the fuel tank up-
Hypoid gear oils rated ÒGL-5Ó or ÒGL-6Ó EAU02998
ward and position it away from the
may also be used.
Air filter
air filter. (Do not remove the fuel
The air filter should be cleaned at the
tank.)
5. Install and tighten the filler bolt to specified intervals. It should be cleaned EW000071
the specified torque. more frequently if you are riding in un-
usually wet or dusty areas.
Tightening torque: l Support the fuel tank carefully
1. Remove the seats. (See page 3-7
Oil filler bolt: during this procedure.
for seat removal and installation
23 Nm (2.3 mákg) l Do not tilt the fuel tank too
procedures.)
much or pull it too hard be-
2. Remove the fuel tank bolts.
6. After replacing the final gear oil, be cause the fuel hose connec-
sure to check for oil leakage. tions may become loose
causing fuel leakage.

4. Remove the air filter case cover


screw.

6-10
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


7. Reassemble by reversing the re-
moval procedure.
EC000082

CAUTION:
l Make sure the air filter is prop-
erly seated in the air filter case.
l The engine should never be run
without the air filter installed.
1. Air filter case cover Excessive piston and/or cylin-
2. Tab 6. Pull out the air filter element and der wear may result.
3. Holder
4. Air filter
tap it lightly to remove most of the
dust and dirt. Blow out the remain-
5. Slide the air filter case cover so as
ing dirt with compressed air as
to unhook the tab on the rear of shown. If the air filter element is
the cover from the holder on the damaged, replace it.
frame. Then lift the air filter case
cover upward without removing it.

6-11
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00630

Carburetor adjustment
The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Most adjustments
should be left to a Yamaha dealer who
has the professional knowledge and
experience to do so. However, the idle
speed may be adjusted by the owner
1. Washer as part of routine maintenance.
2. Rubber damper EC000095

3. Spacer CAUTION:
EW000131
The carburetors were set at the
Yamaha factory after many tests. If
Make sure that the fuel hoses and they are changed, poor engine per-
vacuum hose are properly connect- formance and damage may result.
ed, in place and not pinched. If a
hose is damaged, be sure to replace
it.
EC000086

CAUTION:
When reinstalling the fuel tank hold-
ing bolts, make sure that the wash-
ers, damper rubbers and spacers
are positioned properly.

6-12
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01168

Idle speed adjustment


NOTE:
A diagnostic tachometer must be used
for this procedure.

1. Attach the tachometer. Start the


engine and warm it up for a few
minutes at approximately 1,000 to
2,000 r/min. Occasionally rev the 1. Throttle stop screw a. Free play
engine to 4,000 to 5,000 r/min. 2. Set the idle to the specified engine EAU00635

The engine is warm when it quick- speed by adjusting the throttle Throttle cable free play
ly responds to the throttle. stop screw. Turn the screw in di- inspection
rection a to increase engine There should be a free play of 3 ~
speed and in direction b to de- 5 mm at the throttle grip. If the free play
crease engine speed. is incorrect, ask a Yamaha dealer to
make this adjustment.
Standard idle speed:
1,150 ~ 1,250 r/min

NOTE:
If the specified idle speed cannot be
obtained by performing the above ad-
justment, consult a Yamaha dealer.

6-13
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00637 EAU00647

Valve clearance adjustment Tires Maximum load*


220 kg (except for CH, A)
218 kg (for CH, A)
The correct valve clearance changes To ensure maximum performance,
Cold tire pressure Front Rear
with use, resulting in improper fuel/air long service, and safe operation, note
200 kPa 225 kPa
supply or engine noise. To prevent this, the following: Up to 90 kg (2.00 kg/cm2, (2.25 kg/cm2,
the valve clearance must be adjusted 2.00 bar) 2.25 bar)

Tire air pressure 200 kPa 250 kPa


regularly. This adjustment however, 90 kg load ~
(2.00 kg/cm2, (2.50 kg/cm2,
should be left to a professional Always check and adjust the tire pres- Maximum load*
2.00 bar) 2.50 bar)
Yamaha service technician. sure before operating the motorcycle. * Load is the total weight of cargo, rider, passenger
EW000082 and accessories.

Tire inflation pressure should be


checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed.

6-14
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EW000083
FRONT
Manufacturer Size Type
Proper loading of your motorcycle Bridgestone 3.00-19 49S L303A
is important for several characteris- Dunlop 3.00-19 49S F14G
tics of your motorcycle, such as REAR
handling, braking, performance and Manufacturer Size Type
safety. Do not carry loosely packed Bridgestone 140/90-15 M/C 70S G508
items that can shift. Securely pack Dunlop 140/90-15 M/C 70S K425
your heaviest items close to the
center of the motorcycle, and dis- a. Tread depth Minimum tire tread depth
1.6 mm
1. Side wall (front and rear)
tribute the weight evenly from side
to side. Properly adjust the suspen- Tire inspection
sion for your load, and check the Always check the tires before operating NOTE:
condition and pressure of your tires. the motorcycle. If center tread depth These limits may be different by regula-
NEVER OVERLOAD YOUR MOTOR- reaches the limit as shown, if the tire tion from country to country. If so, con-
CYCLE. Make sure the total weight has a nail or glass fragments in it, or if form to the limits specified by the
of the cargo, rider, passenger, and the side wall is cracked, contact a regulations of your own country.
accessories (fairing, saddlebags, Yamaha dealer immediately and have
etc. if approved for this model) does the tire replaced.
not exceed the maximum load of the
motorcycle. Operation of an over-
loaded motorcycle could cause tire
damage, an accident, or even injury.

6-15
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00681 EAU00685

Wheels
l Operating the motorcycle with To ensure maximum performance,
excessively worn tires decrease long service, and safe operation, note
riding stability and can lead to the following:
loss of control. Have excessive- l Always inspect the wheels before

ly worn tires replaced by a a ride. Check for cracks, bends or


Yamaha dealer immediately. warpage of the wheel. Be sure the
Brakes, tires, and related wheel spokes are tight and undamaged.
parts replacement should be If any abnormal condition exists in
left to a Yamaha Service Techni- a wheel, consult a Yamaha dealer.
cian. Do not attempt even small repairs
l Patching a punctured tube is to the wheel. If a wheel is de-
not recommended. If it is abso- formed or cracked, it must be re-
lutely necessary to do so, use placed.
l Tires and wheels should be bal-
great care and replace the tube
as soon as possible with a good anced whenever either one is
quality replacement. changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse han-
dling characteristics, and short-
ened tire life.
l Ride at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.

6-16
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Locknut 1. Locknut 1. Adjusting bolt


2. Adjusting bolt 2. Adjusting nut 2. Locknut
c. Free play c. Free play
If the specified free play cannot be ob-
EAU00694 EAU00696
tained, proceed with the following steps.
Clutch lever free play Front brake lever free play
4. Loosen the locknut at the clutch le-
adjustment ver.
adjustment
The clutch lever free play should be ad- The free play at the front brake lever
5. Turn the adjusting bolt at the
justed to 10 ~ 15 mm. clutch lever in direction a to loos- should be 2 ~ 5 mm.
1. Loosen the locknut at the clutch le- en the cable. 1. Loosen the locknut.
ver. 2. Turn the adjusting bolt in direction
6. Loosen the locknut at the crank-
2. Turn the adjusting bolt at the a to increase free play or in direc-
case side.
clutch lever in direction a to in- 7. Turn the adjusting nut at the tion b to decrease free play.
crease free play or in direction b 3. After adjusting, tighten the locknut.
crankcase in direction a to in-
to decrease free play. crease free play or in direction b
3. Tighten the locknut at the clutch to decrease free play.
lever.
8. Tighten the locknut at the crank-
case and the clutch lever.

6-17
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EW000099

l Check the brake lever free play.


Be sure the brake is working
properly.
l A soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake sys-
tem. This air must be removed
by bleeding the brake system 1. Footrest 1. Adjusting bolt
2. Pedal height 2. Locknut
before the motorcycle is operat- a. Free play
ed. Air in the system will cause 1. Loosen the locknut.
EAU00711
greatly diminished braking ca- 2. Turn the adjusting bolt in direction
Rear brake pedal height and
pability and can result in loss of a to raise pedal height or in direc-
free play adjustment tion b to lower pedal height.
control and an accident. Have a EW000104

Yamaha dealer inspect and 3. Tighten the locknut.


EW000105
bleed the system if necessary.
It is advisable to have a Yamaha
dealer make this adjustment. After adjusting the pedal height ad-
The brake pedal height should be ad- just brake pedal free play.
justed before adjusting the brake pedal
free play.
Pedal height
The brake pedal should be positioned
approximately 38 mm above the top of
the footrest.

6-18
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Adjusting nut 1. Brake light switch 1. Wear indicator groove (´ 2)


2. Adjusting nut 2. Wear limit
Free play
EAU00713 EAU00720
The brake pedal free play should be
Brake light switch adjustment Checking the front brake pads
adjusted to 20 ~ 30 mm at the brake
pedal end. Turn the adjusting nut on
The rear brake light switch is activated and rear brake shoes
by the brake pedal and is properly ad-
the brake rod in direction a to increase
justed when the brake light comes on EAU01119
free play or in direction b to decrease Front brake
just before braking takes effect. To ad-
free play. Wear indicator grooves are provided
just the rear brake light switch, hold the
switch body so it does not rotate while on each brake pad. These indicators
turning the adjusting nut. Turn the ad- allow checking of brake pad wear with-
justing nut in direction a to make the out disassembling the brake. Inspect
brake light come on earlier. Turn the the grooves. If they have almost disap-
adjusting nut in direction b to make the peared, ask a Yamaha dealer to re-
brake light come on later. place the pads.

6-19
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


l Use only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.

Recommended brake fluid: DOT 4

NOTE:
1. Wear limit 1. Minimum level mark If DOT 4 is not available, DOT 3 can be
2. Wear indicator EAU00732
used.
EAU00727 Inspecting the brake fluid
Rear brake
level l Refill with the same type of brake
Apply the brake and inspect the wear fluid. Mixing fluids may result in a
Insufficient brake fluid may let air enter
indicator. harmful chemical reaction and
the brake system, possibly causing the
If the indicator reaches the wear limit lead to poor brake performance.
brakes to become ineffective.
line, ask a Yamaha dealer to replace Be careful that water does not en-
Before riding, check that the brake fluid l
the shoes. ter the master cylinder when refill-
is above the minimum level and fill
when necessary. ing. Water will significantly lower
Observe these precautions: the boiling point of the fluid and
l When checking the fluid level, may result in vapor lock.
make sure the top of the master
cylinder is level by turning the han-
dlebars.

6-20
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00742 EAU02962

l Brake fluid may deteriorate paint- Brake fluid replacement Cable inspection and
ed surfaces or plastic parts. Al- The brake fluid should be replaced only lubrication
ways clean up spilled fluid by trained Yamaha service personnel. EW000112

immediately. Have the Yamaha dealer replace the


l Have a Yamaha dealer check the following components during periodic Damage to the outer housing of ca-
cause if the brake fluid level goes maintenance or when they are dam- bles may lead to internal rusting and
down. aged or leaking: interfere with the cable movement.
l oil seals (every two years) Replace damaged cables as soon as
l brake hoses (every four years) possible to prevent unsafe condi-
tions.

Lubricate the cables and cable ends. If


a cable does not operate smoothly, ask
a Yamaha dealer to replace it.

Recommended lubricant:
Engine oil

6-21
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00773

Throttle cable and grip


lubrication
The throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With EAU02984 EAU02985

the throttle grip disassembled, coat the Brake and shift pedal Brake and clutch lever
metal surface of the grip assembly with lubrication lubrication
a suitable all-purpose grease. Lubricate the pivoting parts. Lubricate the pivoting parts.

Recommended lubricant: Recommended lubricant:


Engine oil Engine oil

6-22
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU00790 EAU02939

Rear suspension lubrication Front fork inspection


Lubricate the pivoting parts. Visual check
EW000115

Recommended lubricant:
Molybdenum disulfide grease Securely support the motorcycle so
there is no danger of it falling over.

Check for scratches or damage on the


EAU02986
inner tube and excessive oil leakage
Sidestand lubrication from the front fork.
Lubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.

Recommended lubricant:
Engine oil
EW000113

If the sidestand does not move


smoothly, consult a Yamaha dealer.

6-23
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01144

Wheel bearings
If there is play in the front or rear wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer in-
spect the wheel bearings.

EAU00794

Operation check Steering inspection


1. Place the motorcycle on a level Periodically inspect the condition of the
place. steering. Worn out or loose steering
2. Hold the motorcycle in an upright bearings may be dangerous. Place a
position and apply the front brake. stand under the engine to raise the
3. Push down hard on the handle- front wheel off the ground. Hold the
bars several times and check if the lower end of the front forks and try to
fork rebounds smoothly. move them forward and backward. If
EC000098
any free play can be felt, ask a Yamaha
CAUTION: dealer to inspect and adjust the steer-
If any damage or unsmooth move- ing. Inspection is easier if the front
ment is found with the front fork, wheel is removed.
consult a Yamaha dealer. EW000115

Securely support the motorcycle so


there is no danger of it falling over.

6-24
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EC000099 EW000116

CAUTION:
When inspecting the battery, be Battery electrolyte is poisonous and
sure the breather hose is routed cor- dangerous, causing severe burns,
rectly. If the breather hose is posi- etc. It contains sulfuric acid. Avoid
tioned in such a way as to cause contact with skin, eyes or clothing.
battery electrolyte or gas to exit ANTIDOTE:
onto the frame, structural and cos- l EXTERNAL: Flush with water.
metic damage to the motorcycle can l INTERNAL: Drink large quanti-
1. Battery ties of water or milk. Follow with
2. Pass through the battery case
occur.
3. Pass through the frame milk of magnesia, beaten egg,
4. Pass through the cable guide or vegetable oil. Call a physi-
5. Pass through the engine bracket cian immediately.
6. Battery breather hose
l EYES: Flush with water for
EAU00798
15 minutes and get prompt
Battery
medical attention.
Check the level of the battery electro-
Batteries produce explosive gases.
lyte and make sure that the terminals
Keep sparks, flame, cigarettes etc.,
are tight. Fill with distilled water if the
away. Ventilate when charging or
electrolyte level is low. If the motor-
using in an enclosed space. Always
cycle is equipped with optional electri-
shield your eyes when working near
cal accessories, the battery tends to
batteries. KEEP OUT OF REACH OF
discharge more quickly, so be sure to
CHILDREN.
recharge it periodically.

6-25
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


Battery storage
l When the motorcycle will not be
used for a month or longer, re-
move the battery, fully charge it
and store it in a cool, dry place.
Completely recharge the battery
before reinstalling.
l If the battery will be stored for

1. Maximum level mark longer than two months, check the


2. Minimum level mark specific gravity of the fluid at least
Replenishing the battery fluid once a month and recharge the
A poorly maintained battery will cor- battery when it is too low.
l Always make sure the connec-
rode and discharge quickly. The bat-
tery fluid should be checked at least tions are correct when putting the
once a month. The level should be be- battery back in the motorcycle.
tween the minimum level and maxi- Make sure the breather hose is
mum level marks. Use only distilled properly connected and is not
water if refilling is necessary. damaged or obstructed.
EC000100

CAUTION:
Normal tap water contains minerals
which are harmful to a battery;
therefore, refill only with distilled
water.

6-26
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EC000103

CAUTION:
Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire.

1. Main fuse 1. Screw (´ 2)


2. Headlight fuse EAU01524
3. Signaling system fuse
4. Ignition fuse
Specified fuses: Headlight bulb replacement
5. Spare fuse (´ 2) Main fuse: 30 A This motorcycle is equipped with a
EAU00818
Headlight fuse: 15 A quartz bulb headlight.
Fuse replacement Signaling system fuse: 15 A If the headlight bulb burns out, replace
The fuse box is located under the rider Ignition fuse: 15 A the bulb as follows:
seat. If any fuse is blown, turn off the 1. Remove the headlight unit screws.
main switch and the switch of the circuit
in question. Install a new fuse of the
specified amperage. Turn on the
switches and check if the electrical de-
vice operates. If the fuse immediately
blows again, consult a Yamaha dealer.

6-27
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR

1. Connector 1. Bulb holder 1. DonÕt touch


2. Bulb cover
3. Turn the bulb holder counterclock- EC000105

2. Remove the connector, the head- wise to remove it and remove the CAUTION:
light unit and then the bulb cover. defective bulb. Avoid touching the glass part of a
EW000119
bulb. Keep it free from oil; other-
wise, the transparency of the glass,
Keep flammable products and your life of the bulb, and luminous flux
hands away from a bulb while it is will be adversely affected. If oil gets
on, as it is hot. Do not touch a bulb on a bulb, thoroughly clean it with a
until it cools down. cloth moistened with alcohol or lac-
quer thinner.
4. Put a new bulb into position and
secure it in place with the bulb 5. Install the bulb cover, connector
holder. and headlight unit.
Ask a Yamaha dealer to adjust the
headlight beam if necessary.

6-28
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01008

Troubleshooting
Although Yamaha motorcycles receive
a rigid inspection before shipment from
1 the factory, trouble may occur during
1 operation.
1
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
1. Screw (´ 2) 1. Bulb (´ 2) shooting chart describes a quick, easy
EAU00855
2. Push the bulb inward and turn it procedure for making checks.
Turn signal and taillight bulb counterclockwise. If your motorcycle requires any repair,
replacement bring it to a Yamaha dealer. The skilled
3. Place a new bulb in the socket.
1. Remove the screws and the lense. Push the bulb inward and turn it technicians at a Yamaha dealership
clockwise until it engages into the have the tools, experience, and know-
how to properly service your motor-
socket.
4. Install the lense and the screws. cycle. Use only genuine Yamaha parts
EC000108 on your motorcycle. Imitation parts may
CAUTION: look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
Do not over-tighten the screws as
shorter service life and can lead to ex-
the lense may break.
pensive repair bills.

6-29
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame

PERIODIC MAINTENANCE AND MINOR REPAIR


EAU01562

Troubleshooting chart
EW000125

Never check the fuel system while smoking or in the vicinity of an open flame.

1. Fuel
Enough fuel. Go to compression check.
Check if there is fuel
in the fuel tank.
No fuel. Supply fuel. Engine doesnÕt start, go to compression check.

2. Compression
There is compression. Go to ignition check.
Use electric starter.
Ask a Yamaha dealer to
No compression.
inspect.

3. Ignition Wipe clean with dry cloth and correct Open throttle half-way and start
Wet.
Remove spark spark gap or replace spark plugs. the engine.
plugs and
check electrode.
Engine doesnÕt start, go to battery
Dry. Ask a Yamaha dealer to inspect.
check.

4. Battery Engine turns over


Battery good.
quickly.
Engine doesnÕt start, ask a Yamaha
Use the electric starter.
dealer to inspect.
Engine turns over Check fluid, recharge,
slowly. check connections.

6-30
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-7TOC.frame

MOTORCYCLE CARE AND STORAGE

Care ................................................................................................... 7-1


Storage............................................................................................... 7-4
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-7.frame

MOTORCYCLE CARE AND STORAGE EAU01521

Care Before cleaning Cleaning


The exposure of its technology makes 1. Cover up the muffler outlets with After normal use
a motorcycle charming but also vulner- plastic bags. Remove dirt with warm water, a neutral
able. Although high-quality compo- 2. Make sure that all caps and covers detergent and a soft clean sponge,
nents are used, they are not all rust-re- as well as all electrical couplers then rinse with plenty of clean water.
sistant. While a rusty exhaust pipe may and connectors, including the Use a tooth or bottle brush for hard-to-
remain unnoticed on a car, it does look spark plug caps, are tightly in- reach parts. Tougher dirt and insects
unattractive on a motorcycle. Frequent stalled. will come off more easily if the area is
and proper care, however, will keep 3. Remove extremely stubborn dirt, covered with a wet cloth for a few min-
your motorcycle looking good, extend like oil burnt onto the crankcase, utes before cleaning.
its life and maintain its performance. with a degreasing agent and a
Moreover, the warranty states that the brush, but never apply such prod-
vehicle must be properly taken care of. ucts onto seals, gaskets and
For all these reasons, it is recommend- wheel axles. Always rinse the dirt
ed that you observe the following and degreaser off with water.
cleaning and storing precautions.

7-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-7.frame

MOTORCYCLE CARE AND STORAGE


ECA00010

CAUTION: l Do not use any harsh chemical l For motorcycles equipped with
products on plastic parts. Be a windshield: Do not use strong
l Avoid using strong acidic wheel sure to avoid using cloths or cleaners or hard sponges as
cleaners, especially on spoked
sponges which have been in they will cause dulling or
wheels. If you do use such contact with strong or abrasive scratching. Some cleaning
products for hard-to-remove cleaning products, solvent or compounds for plastic may
dirt, do not leave it on any long-
thinner, fuel (gasoline), rust re- leave scratches on the wind-
er than instructed, then thor- movers or inhibitors, brake flu- shield. Test the product on a
oughly rinse it off with water, id, antifreeze or electrolyte. small hidden part of the wind-
immediately dry the area and
l Do not use high-pressure wash- shield to make sure they do not
apply a corrosion protection ers or steam-jet cleaners since leave any marks. If the wind-
spray. they cause water seepage and shield is scratched, use a quali-
l Improper cleaning can damage
deterioration in the following ar- ty plastic polishing compound
windshields, cowlings, panels eas: seals (of wheel bearings, after washing.
and other plastic parts. Use swingarm bearings, forks and
only a soft, clean cloth or
brakes), electric components
sponge with mild detergent and (couplers, connectors, instru- After riding in the rain, near the sea or
water to clean plastic. ments, switches and lights), on salt-sprayed roads
breather hoses and vents. Since sea salt or salt sprayed on the
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)

7-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-7.frame

MOTORCYCLE CARE AND STORAGE


EWA00001

1. Clean your motorcycle with cold After cleaning


water and soap after the engine 1. Dry the motorcycle with a chamois
Make sure that there is no oil or wax
has cooled down. or an absorbing cloth.
on the brakes and tires. If neces-
ECA00012
2. Use a chrome polish to shine
CAUTION: sary, clean the brake discs and lin-
chrome, aluminum and stainless-
ings with a regular brake disc
Do not use warm water since it in- steel parts, including the exhaust
cleaner or acetone, and wash the
creases the corrosive action of the system. (Even the thermally in-
tires with warm water and mild soap.
salt. duced discoloring of stainless-
Then, carefully test the motorcycle
steel exhaust systems can be re-
for its braking performance and cor-
2. Be sure to apply a corrosion pro- moved through polishing.)
nering behavior.
tection spray on all (even chrome- 3. To prevent corrosion, it is recom-
and nickel-plated) metal surfaces mended to apply a corrosion pro-
to prevent corrosion. tection spray on all (even chrome-
and nickel-plated) metal surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing it or covering it.

7-3
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-7.frame

MOTORCYCLE CARE AND STORAGE


ECA00013

CAUTION: Storage Long-term


Short-term Before storing your motorcycle for sev-
l Apply spray oil and wax spar- eral months:
Always store your motorcycle in a cool,
ingly and wipe off any excess. 1. Follow all the instructions in the
dry place and, if necessary, protect it
l Never apply oil or wax on rub- ÒCareÓ section of this chapter.
against dust with a porous cover.
ber and plastic parts, but treat ECA00014 2. Drain the carburetor float cham-
them with a suitable care prod- CAUTION: bers by loosening the drain bolts;
uct. this will prevent fuel deposits from
l Avoid using abrasive polishing l Storing the motorcycle in a
poorly ventilated room or cov- building up. Pour the drained fuel
compounds as they wear away into the fuel tank.
the paint. ering it with a tarp while it is still
wet will allow water and humidi- 3. Only for motorcycles equipped
ty to seep in and cause rust. with a fuel cock which has an
NOTE:
l To prevent corrosion, avoid ÒOFFÓ position: Turn the fuel cock
Consult a Yamaha dealer for advice on
damp cellars, stables (because to ÒOFFÓ.
what products to use.
of the presence of ammonia) 4. Fill up the fuel tank and add fuel
and areas where strong chemi- stabilizer (if available) to prevent
cals are stored. the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to pro-
tect the cylinders, piston rings, etc.
from corrosion.

7-4
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-7.frame

MOTORCYCLE CARE AND STORAGE


a. Remove the spark plug caps and 6. Lubricate all control cables and 9. Remove the battery and fully
spark plugs. the pivoting points of all levers and charge it. Store it in a cool, dry
b. Pour a teaspoonful of engine oil pedals as well as of the side- place and recharge it once a
into each spark plug bore. stand/centerstand. month. Do not store the battery in
c. Install the spark plug caps onto 7. Check and, if necessary, correct an excessively cold or warm place
the spark plugs and place the the tire air pressure, then raise the (less than 0ûC or more than 30ûC).
spark plugs on the cylinder head motorcycle so that both of its For more information, see ÒBattery
so that the electrodes are wheels are off the ground. Alterna- storageÓ in the chapter ÒPERIODIC
grounded. (This will limit sparking tively, turn the wheels a little every MAINTENANCE AND MINOR
during the next step.) month in order to prevent the tires REPAIRSÓ.
d. Turn the engine over several from becoming degraded in one
NOTE:
times with the starter. (This will spot.
Make any necessary repairs before
coat the cylinder walls with oil.) 8. Cover up the muffler outlets with
storing the motorcycle.
e. Remove the spark plug caps from plastic bags to prevent moisture
the spark plugs, install the spark from entering.
plugs and then the spark plug
caps.
EWA00003

When turning the engine over, be


sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking.

7-5
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-8TOC.frame

SPECIFICATIONS

Specifications ..................................................................................... 8-1


HOW TO USE THE CONVERSION TABLE ...................................... 8-5
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-8.frame

SPECIFICATIONS EAU01038

Specifications
Model XV535 Engine oil
Dimensions Type
-20û -10û 0û 10û 20û 30û 40û 50ûC
Overall length 2,225 mm
(except for CH, S, SF, N) SAE 10W/30

2,250 mm (for CH, S, SF, N) SAE 10W/40


Overall width 780 mm SAE 15W/40
Overall height 1,120 mm
SAE 20W/40
Seat hight 720 mm
SAE 20W/50
Wheelbase 1,520 mm
Ground clearance 160 mm Recommended engine oil
classiÞcation API Service SE, SF, SG type or
Minimum turning radius 2,900 mm
higher
Basic weight (with oil and full
fuel tank) 195 kg (except for CH, A) CAUTION:
197 kg (for CH, A) Be sure to use motor oils that do not contain anti-fric-
Engine tion modifiers. Passenger car motor oils (often labeled
ÒEnergy ConservingÓ) contain anti-friction additives
Engine type Air-cooled 4-stroke, SOHC which will cause clutch and/or starter clutch slippage,
Cylinder arrangement V type 2-cylinder resulting in reduced component life and poor engine
performance.
Displacement 535 cm3
Bore ´ Stroke 76.0 ´ 59.0 mm Quantity
Compression ratio 9:1 Periodic oil change 2.6 L
Starting system Electric starter With oil Þlter replacement 2.8 L
Lubrication system Wet sump Total amount 3.2 L

8-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-8.frame

SPECIFICATIONS
Final gear oil Transmission type Constant mesh 5-speed
Type SAE 80 API ÒGL-4Ó hypoid gear Operation Left foot operation
oil Gear ratio
Quantity 0.19 L 1st 2.714
Air filter Dry type element 2nd 1.900
Fuel 3rd 1.458
Type Regular unleaded gasoline 4th 1.167
Fuel tank capacity 13.5 L 5th 0.967
Reserve amount 2.5 L Chassis
Carburetor Frame type Pressed backbone
Type ´ quantity BDS34 ´ 2 Caster angle 31.5û
Manufacturer MIKUNI Trail 125 mm
Spark plug Tires
Type/Manufacturer Except for CH: Front
BPR6ES / NGK or
W20EPR-U / DENSO Type With tube
Size 3.00-19 49S
For CH: Manufacturer/
BPR7ES / NGK or model Bridgestone / L303A
W22EPR-U / DENSO
Dunlop / F14G
Gap 0.7 ~ 0.8 mm
Rear
Clutch type Wet, multiple-disc
Type With tube
Transmission
Size 140/90-15M/C 70S
Primary reduction system Spur gear
Manufacturer/
Primary reduction ratio 1.944 model Bridgestone / G508
Secondary reduction system Shaft drive Dunlop / K425
Secondary reduction ratio 3.071

8-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-8.frame

SPECIFICATIONS
Maximum load* 220 kg (except for CH, A) Rear
218 kg (for CH, A) Type Drum brake
Air pressure (cold tire) Operation Right foot operation
Up to 90 kg load* Suspension
Front 200 kPa (2.00 kg/cm2, 2.00 bar) Front
Rear 225 kPa (2.25 kg/cm2, 2.25 bar) Type Telescopic fork
90 kg load ~ maximum Rear
load* Type Swingarm
Front 200 kPa (2.00 kg/cm2, 2.00 bar)
Shock absorbers
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
Front Coil spring/oil damper
* Load is total weight of cargo, rider, passenger and accessories. Rear Coil spring/oil damper
Wheels
Wheel travel
Front
Front 150 mm
Type Spoke Rear 85 mm
Size 19 ´ MT1.85
Electrical system
Rear
Ignition system T.C.I. (digital)
Type Spoke Charging system
Size 15M/C ´ MT3.00
Type A.C. magneto
Brakes
Standard output 14 V, 24 A @ 5,000 r/min
Front Battery
Type Single disc brake
Type GM12AZ-3A-2
Operation Right hand operation
Voltage, capacity 12 V, 12 AH
Fluid DOT 4 or DOT 3 Headlight type Quartz bulb (halogen)

8-3
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-8.frame

SPECIFICATIONS
Bulb voltage, wattage ´ quantity
Headlight 12 V, 60/55 W ´ 1
Auxiliary light 12 V, 4 W ´ 1 (except for GB)
12 V, 3.4 W ´ 1 (for GB)
Tail/brake light 12 V, 5/21 W ´ 2
Front ßasher light 12 V, 21 W ´ 2
Rear ßasher light 12 V, 21 W ´ 2
Meter light 14 V, 3 W ´ 1
Neutral indicator light 14 V, 3 W ´ 1
High beam indicator light 12 V, 1.7 W ´ 1
Turn indicator light 14 V, 3 W ´ 1
Fuses
Main fuse 30 A
Ignition fuse 15 A
Signaling system fuse 15 A
Headlight fuse 15 A

8-4
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-8.frame

SPECIFICATIONS
EAU01064

HOW TO USE THE CONVERSION TABLE CONVERSION TABLE


All specification data in this manual are listed in SI and METRIC TO IMPERIAL
METRIC UNITS. Metric unit Multiplier Imperial unit
Use this table to convert METRIC unit data to IMPERIAL mákg 7.233 ftálb
unit data. Torque
mákg 86.794 inálb
cmákg 0.0723 ftálb
Ex. cmákg 0.8679 inálb
kg 2.205 lb
Weight
METRIC MULTIPLIER IMPERIAL g 0.03527 oz
Speed km/hr 0.6214 mph
**mm ´ 0.03937 = **in
km 0.6214 mi
m 3.281 ft
2 mm ´ 0.03937 = 0.08 in Distance m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume / cc (cm3) 0.06102 cuáin
Capacity lt (liter) 0.8799 qt (IMP liq.)
lt (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Misc. kg/cm2 14.2234 psi (lb/in2)
Centigrade (°C) 9/5 + 32 Fahrenheit (°F)

8-5
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-9TOC.frame

CONSUMER INFORMATION

Identification number records............................................................. 9-1


Key identification number................................................................... 9-1
Vehicle identification number ............................................................. 9-1
Model label......................................................................................... 9-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-9.frame

CONSUMER INFORMATION EAU01039

EAU02944

Identification number records


Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION 1. Key identification number 1. Vehicle identification number
NUMBER: EAU01042 EAU01043

Key identification number Vehicle identification number


The key identification number is The vehicle identification number is
stamped on the key. Record this num- stamped into the steering head pipe.
ber in the space provided and use it for Record this number in the space pro-
2. VEHICLE IDENTIFICATION
reference when obtaining a new key. vided.
NUMBER:

The vehicle identification number is


used to identify your motorcycle and
may be used to register your motor-
3. MODEL LABEL INFORMATION:
cycle with the licensing authority in
your state.

9-1
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-9.frame

CONSUMER INFORMATION

1. Model label
EAU01050

Model label
The model label is affixed to the frame
under the seat. (See page 3-7 for seat
removal procedures.) Record the infor-
mation on this label in the space pro-
vided. This information will be needed
to order spare parts from your Yamaha
dealer.

9-2
L /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/XV535IX.-

INDEX

A Front brake lever free play Neutral indicator light ....................... 3-1
Air filter .................................................6-10 adjustment ........................................ 6-17 Turn indicator light ............................ 3-1
Front fork inspection ............................ 6-23 Inspecting the brake fluid level ............ 6-20
B Fuel ........................................................ 3-5
Battery ..................................................6-25 K
Fuel reserve switch ................................ 3-3
Brake and clutch lever lubrication ........6-22 Key identification number ...................... 9-1
Fuel tank cap ......................................... 3-5
Brake and shift pedal lubrication ..........6-22 Fuse replacement ................................ 6-27 L
Brake fluid replacement ........................6-21
Left view ................................................. 2-1
Brake light switch adjustment ...............6-19 G
Lights switch .......................................... 3-3
Give safety the right of way ................... 1-1
C M
Cable inspection and lubrication ..........6-21 H
Main switch ............................................ 3-1
Carburetor adjustment ..........................6-12 Handlebar switches ............................... 3-2
Model label ............................................ 9-2
Care ........................................................7-1 Dimmer switch ................................. 3-2
Checking the front brake pads and Engine stop switch ........................... 3-3 N
rear brake shoes ................................6-19 Fuel reserve switch .......................... 3-3 Neutral indicator light ............................. 3-1
Clutch lever ............................................3-3 Horn switch ...................................... 3-2
P
Clutch lever free play adjustment .........6-17 Lights switch .................................... 3-3
Parking ................................................... 5-6
Controls/Instruments ..............................2-3 Pass switch ...................................... 3-2
Pass switch ............................................ 3-2
Start switch ...................................... 3-3
D Turn signal switch ............................ 3-2
Periodic maintenance and lubrication .... 6-2
Dimmer switch ........................................3-2 Pre-operation check list ......................... 4-1
Headlight bulb replacement ................. 6-27
E Helmet holder ........................................ 3-8 R
Engine break-in ......................................5-5 High beam indicator light ....................... 3-1 Rear brake pedal ................................... 3-4
Engine oil ................................................6-7 Horn switch ............................................ 3-2 Rear brake pedal height and free play
Engine stop switch .................................3-3 adjustment ......................................... 6-18
I
Rear shock absorber adjustment ........... 3-9
F Identification number records ................ 9-1
Rear suspension lubrication ................ 6-23
Final gear oil ...........................................6-9 Idle speed adjustment ......................... 6-13
Recommended shift points
Front brake lever ....................................3-4 Indicator lights ....................................... 3-1
(for Switzerland only) .......................... 5-4
High beam indicator light ................. 3-1
Right view .............................................. 2-2
R /Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/XV535IX.-

INDEX

S Turn signal and taillight bulb


Seats ..................................................... 3-7 replacement ...................................... 6-29
Shift pedal .............................................. 3-4 Turn signal switch .................................. 3-2
Shifting ................................................... 5-4 V
Sidestand ............................................... 3-9 Valve clearance adjustment ................. 6-14
Sidestand lubrication ........................... 6-23
Vehicle identification number ................. 9-1
Sidestand/clutch switch operation
check ................................................. 3-10 W
Spark plugs ............................................ 6-5 Wheel bearings .................................... 6-24
Specifications ........................................ 8-1 Wheels ................................................. 6-16
Speedometer ......................................... 3-2
Start switch ............................................ 3-3
Starter (choke) Ò Ó .............................. 3-6
Starting a warm engine .......................... 5-3
Starting the engine ................................ 5-1
Steering inspection .............................. 6-24
Steering lock .......................................... 3-6
Storage .................................................. 7-4
T
Throttle cable and grip lubrication ....... 6-22
Throttle cable free play inspection ....... 6-13
Tips for reducing fuel consumption ........ 5-5
Tires ..................................................... 6-14
Tool kit ................................................... 6-1
Troubleshooting ................................... 6-29
Troubleshooting chart .......................... 6-30
Turn indicator light ................................. 3-1
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER PRINTED IN JAPAN
99 · 5 - 0.3 × 1 CR
(E)

You might also like