OWNER’S MANUAL XV535 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 · 7 - 0.
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E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM INTRODUCTION EAU03338 Welcome to the Yamaha world of motorcycling! As the owner of an XV535, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and 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 advantages of your XV535.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM IMPORTANT MANUAL INFORMATION 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.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM IMPORTANT MANUAL INFORMATION EAU03337 XV535 OWNER’S MANUAL © 2000 by Yamaha Motor Co., Ltd. 1st Edition, July 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
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E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY.................................................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM GIVE SAFETY THE RIGHT OF WAY EAU00021 1- 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 ignore the laws of physics. 1 Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM DESCRIPTION Left view ............................................................................................. 2-1 Right view........................................................................................... 2-2 Controls and instruments ...................................................................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM DESCRIPTION EAU00026 2- Left view 2 1. Headlight 2. Air filter element 3. Rider seat 4. Owner’s tool kit 5. Helmet holder 6. Passenger seat 7. Shock absorber spring preload adjusting ring 8. Main switch 9. Starter (choke) lever 10.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM DESCRIPTION Right view 2 11. Rear turn signal light 12. Fuel sub-tank 13. Fuel tank (page 6-33) 14. Front turn signal light 15. Brake pedal 16.
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM DESCRIPTION Controls and instruments 2 1. Clutch lever 2. Speedometer unit 3. Brake lever 4. Throttle grip 5. Right handlebar switches 6.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS Main switch ........................................................................................ 3-1 Indicator lights .................................................................................... 3-1 Speedometer unit .............................................................................. 3-2 Handlebar switches ............................................................................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00027 3- 3 EAU00028 Main switch The main switch controls the ignition and lighting systems. The various main switch positions are described below. EAU00036 ON All electrical systems are supplied with power, and the engine can be started. The key cannot be removed. EAU00038 OFF All electrical systems are off. The key can be removed. 1. Push. 2. Release. 3. Turn. 1. High beam indicator light “ 2.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00124 1. Tripmeter reset knob 2. Odometer 3. Tripmeter EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer, an odometer and a tripmeter. The speedometer shows riding speed. The odometer shows the total distance traveled. The tripmeter shows the distance traveled since it was last set to zero with the reset knob.
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch “ ” Push this switch to crank the engine with the starter. EC000005 CAUTION: See page 5-1 for starting instructions prior to starting the engine. @ 3 @ 1. 2. 3. 4.
E_3bt.book Page 4 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Shift pedal 1. Brake lever 1. Brake pedal EAU00157 EAU00158 EAU00162 Shift pedal Brake lever Brake pedal The shift pedal is located on the left side of the engine and is used in combination with the clutch lever when shifting the gears of the 5-speed constant-mesh transmission equipped on this motorcycle. The brake lever is located at the right handlebar grip.
E_3bt.book Page 5 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked. _ _ EWA00025 WARNING Make sure that the fuel tank cap is properly closed before riding. _ 3 1. Unlock. _ EAU03712 Fuel tank cap 1. Fuel tank filler tube 2. Fuel level EAU01183 Fuel Make sure that there is sufficient fuel in the tank.
E_3bt.book Page 6 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. @ @ 3 EAU00191 Recommended fuel: Regular unleaded gasoline with a research octane number of 91 or higher Fuel tank capacity: Total amount: 13.5 L Reserve amount: 2.5 L 1.
E_3bt.book Page 7 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering 1. Open the steering lock cover, and then insert the key. 2. Push the key in, turn it 1/8 turn counterclockwise so that it moves out, and then release it. 3. Remove the key, and then close the lock cover. 3 1. Steering lock 1. Seat lock 2. Unlock. EAU02934 Steering lock EAU02940 Seats To lock the steering 1. Turn the handlebar all the way to right. 2.
E_3bt.book Page 8 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS 3 1. Projection 2. Seat holder To install the passenger seat 1. Insert the projection on the rear of the passenger seat into the seat holder as shown, and then push the front of the seat down to lock it in place. 2. Turn the key counterclockwise, and then remove it. 1. Bolt (× 2) Rider seat To remove the rider seat 1. Remove the passenger seat. 2. Remove the bolts, and then pull the rider seat off. 1.
E_3bt.book Page 9 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00300 Adjusting the shock absorber assemblies Each shock absorber assembly is equipped with a spring preload adjusting ring. EC000015 3 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings. @ 1. Unlock. EAU00260 Helmet holder @ To open the helmet holder, insert the key into the lock, and then turn the key as shown.
E_3bt.book Page 10 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS EAU00330 Sidestand The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the motorcycle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations. (See further down for an explanation of the ignition circuit cut-off system.
E_3bt.book Page 11 Thursday, September 7, 2000 10:01 AM INSTRUMENT AND CONTROL FUNCTIONS CD-01E With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is set to “ 3. Turn the key to “ON”. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? 3 YES NOTE: This check is most reliable if performed with a warmed-up engine. ”. NO The neutral switch may be defective.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM PRE-OPERATION CHECKS Pre-operation check list......................................................................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM PRE-OPERATION CHECKS EAU01114 4- The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM PRE-OPERATION CHECKS ITEM CHECKS PAGE Control cables • Make sure that operation is smooth. • Lubricate if necessary. Wheels and tires • • • • Brake and shift pedals • Make sure that operation is smooth. • Lubricate pedal pivoting points if necessary. 6-25 Brake and clutch levers • Make sure that operation is smooth. • Lubricate lever pivoting points if necessary. 6-25 Sidestand • Make sure that operation is smooth.
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E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM OPERATION AND IMPORTANT RIDING POINTS Starting a cold engine ....................................................................... 5-1 Starting a warm engine ...................................................................... 5-2 Shifting .............................................................................................. 5-3 Recommended shift points (for Switzerland only) ..............................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM OPERATION AND IMPORTANT RIDING POINTS EAU00372 5- EAU00373 @ 5 WARNING ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. ● Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM OPERATION AND IMPORTANT RIDING POINTS 5. After starting the engine, move the starter (choke) lever back halfway. ECA00045 CAUTION: For maximum engine life, never accelerate hard when the engine is cold! @ EAU01258 Starting a warm engine Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. @ 6. When the engine is warm, turn the starter (choke) off.
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM OPERATION AND IMPORTANT RIDING POINTS EC000048 @ 1. Shift pedal N. Neutral position EAU00423 5 Shifting Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the illustration. CAUTION: ● Even with the transmission in the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long distances.
E_3bt.book Page 4 Thursday, September 7, 2000 10:01 AM OPERATION AND IMPORTANT RIDING POINTS EAU00424 Tips for reducing fuel consumption Fuel consumption depends largely on your riding style. Consider the following tips to reduce fuel consumption: ● Thoroughly warm up the engine. ● Turn the starter (choke) off as soon as possible. ● Shift up swiftly, and avoid high engine speeds during acceleration. ● Do not rev the engine while shifting down, and avoid high engine speeds with no load on the engine.
E_3bt.book Page 5 Thursday, September 7, 2000 10:01 AM OPERATION AND IMPORTANT RIDING POINTS 1,000 km and beyond Avoid prolonged full-throttle operation. Vary the speed occasionally. EC000049 CAUTION: If any engine trouble should occur during the engine break-in period, immediately have a Yamaha dealer check the vehicle. EAU00460 Parking When parking, stop the engine, and then remove the key from the main switch.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ....................................................6-1 Periodic maintenance and lubrication chart .........6-2 Checking the spark plugs ....................................6-5 Engine oil and oil filter element ............................6-7 Final gear oil ........................................................6-9 Cleaning the air filter element ............................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00462 6- EAU00464 6 Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of inspection, adjustment, and lubrication are explained on the following pages.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03685 Periodic maintenance and lubrication chart NOTE: ● The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. ● From 50,000 km, repeat the maintenance intervals starting from 10,000 km. ● Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. _ _ CP-03E NO.
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR NO. 6 ITEM 10 * Brake hose 11 * Wheels 12 * Tires 13 * Wheel bearings 14 * Swingarm 15 * Steering bearings 16 * Chassis fasteners 17 Sidestand CHECK OR MAINTENANCE JOB ODOMETER READING (× 1,000 km) 1 10 √ • Check for cracks or damage. • Replace. (See NOTE on page 6-4.) 20 30 40 ANNUAL CHECK √ √ √ √ Every 4 years • Check runout, spoke tightness and for damage.
E_3bt.book Page 4 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR NO. ITEM 24 Final gear oil 25 Front and rear brake switches 26 27 * CHECK OR MAINTENANCE JOB ODOMETER READING (× 1,000 km) 1 10 • Check oil level and vehicle for oil leakage. √ √ • Change. √ • Check operation. √ Moving parts and cables • Lubricate. Lights, signals and * switches • Check operation. • Adjust headlight beam.
E_3bt.book Page 5 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR To check the spark plugs 1. Check that the porcelain insulator around the center electrode on each spark plug is a medium-tolight tan (the ideal color when the motorcycle is ridden normally). 2. Check that all spark plugs installed in the engine have the same color. 1. Spark plug cover 2. Screw (× 2) 1.
E_3bt.book Page 6 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Spark plug: 20 Nm (2.0 m·kg) NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the specified torque as soon as possible. @ a. Spark plug gap To install a spark plug 1.
E_3bt.book Page 7 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02942 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter element replaced at the intervals specified in the periodic maintenance and lubrication chart. To check the engine oil level 1. Place the motorcycle on a level surface and hold it in an upright position. 1. Engine oil level check window 2.
E_3bt.book Page 8 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 1. Oil filter element cover 2. Bolt (× 3) 4. Remove the oil filter element cover by removing the bolts. NOTE: Skip steps 4–6 if the oil filter element is not being replaced. @ 1. O-ring 2. Oil filter element 5. Remove and replace the oil filter element and O-ring. 6.
E_3bt.book Page 9 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03714 NOTE: Make sure that the O-ring is properly seated. @ 7. Install the engine oil drain bolt, and then tighten it to the specified torque. Tightening torque: Engine oil drain bolt: 43 Nm (4.3 m·kg) 6 8. Add the specified amount of the recommended engine oil, and then install and tighten the oil filler cap. Final gear oil Recommended engine oil: See page 8-1.
E_3bt.book Page 10 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The oil level should be at the brim of the filler hole. Recommended final gear oil: Hypoid gear oil SAE 80 (API GL4) or multi-grade hypoid gear oil SAE 80W-90 Oil quantity: 0.19 L _ _ 3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the correct level. NOTE: GL4 is a quality rating. Hypoid gear oils rated GL5 or GL6 may also be used. _ 1.
E_3bt.book Page 11 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Fuel tank 2. Bolt (× 3) 1. Screw 3. Lift the front of the fuel tank to position it away from the air filter case. (Do not remove the fuel tank!) EAU03715 Cleaning the air filter element 6 The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more frequently if you are riding in unusually wet or dusty areas. 1.
E_3bt.book Page 12 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EC000082 _ 1. Air filter element 6. Pull the air filter element out. 7. Lightly tap the air filter element to remove most of the dust and dirt, and then blow the remaining dirt out with compressed air as shown. If the air filter element is damaged, replace it. 8. Insert the air filter element into the air filter case. CAUTION: ● Make sure that the air filter element is properly seated in the air filter case.
E_3bt.book Page 13 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00630 Adjusting the carburetors The carburetors are important parts of the engine and require very sophisticated adjustment. Therefore, most carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience. The adjustment described in the following section, however, may be serviced by the owner as part of routine maintenance.
E_3bt.book Page 14 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00637 Adjusting the valve clearance The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. a.
E_3bt.book Page 15 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03362 CE-01E Tires To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires. Tire air pressure The tire air pressure should be checked and, if necessary, adjusted before each ride. EW000082 @ 6 EWA00012 Tire air pressure (measured on cold tires) Load* @ Front Rear Up to 90 kg 200 kPa 2.00 kg/cm2 2.00 bar 225 kPa 2.
E_3bt.book Page 16 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR Adjust the suspension and tire air pressure with regard to the load. ● Check the tire condition and air pressure before each ride. EW000079 ● @ @ 1. Sidewall a. Tire tread depth Tire inspection The tires must be checked before each ride.
E_3bt.book Page 17 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR Tire information This motorcycle is equipped with tube tires. EAU00681 @ EW000078 @ 6 WARNING ● The front and rear tires should be of the same make and design, otherwise the handling characteristics of the motorcycle cannot be guaranteed. ● After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.
E_3bt.book Page 18 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the locknut at the clutch lever and the crankcase. 1. Locknut 2. Clutch lever free play adjusting bolt c. Clutch lever free play 1. Locknut 2. Clutch lever free play adjusting nut EAU00694 Adjusting the clutch lever free play The clutch lever free play should measure 10–15 mm as shown. Periodically check the clutch lever free play and, if necessary, adjust it as follows. 1.
E_3bt.book Page 19 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknut. EAU00711 EW000099 @ WARNING After adjusting the brake lever free play, check the free play and make sure that the brake is working properly. ● A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle.
E_3bt.book Page 20 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Footrest 2. Distance between brake pedal and footrest a. Brake pedal free play 1. Brake pedal position adjusting bolt 2. Locknut 1. Brake pedal free play adjusting nut 1. Loosen the locknut at the brake pedal. 2. To raise the brake pedal, turn the adjusting bolt in direction a. To lower the brake pedal, turn the adjusting bolt in direction b. 3. Tighten the locknut.
E_3bt.book Page 21 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00720 Checking the front brake pads and rear brake shoes Front The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart. 1. Rear brake light switch 2. Rear brake light switch adjusting nut 1.
E_3bt.book Page 22 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR Observe these precautions: ● When checking the fluid level, make sure that the top of the master cylinder is level by turning the handlebars. ● Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking performance. Rear 1. Rear brake shoe wear limit 2. Rear brake shoe wear indicator 1.
E_3bt.book Page 23 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. ● As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
E_3bt.book Page 24 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03209 Checking and lubricating the throttle grip and cable The operation of the throttle grip and the condition of the throttle cable should be checked before each ride, and the cable should be lubricated or replaced if necessary.
E_3bt.book Page 25 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU03370 6 EAU03164 EAU03165 Checking and lubricating the brake and shift pedals Checking and lubricating the brake and clutch levers Checking and lubricating the sidestand The operation of the brake and shift pedals should be checked before each ride, and the pedal pivots should be lubricated if necessary.
E_3bt.book Page 26 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU00790 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) Lubricating the rear suspension The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
E_3bt.book Page 27 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU02939 EAU00794 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
E_3bt.book Page 28 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication chart. If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings. 2. Hold the lower ends of the front fork legs and try to move them forward and backward.
E_3bt.book Page 29 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the electrolyte is at or below the minimum level mark, add distilled water to raise it to the maximum level mark. EW000116 @ 1. 2. 3. 4. 5. 6. 6 Battery Pass through the battery case. Pass through the frame. Pass through the guide. Pass through the engine bracket. Battery breather hose 1. Maximum level mark 2.
E_3bt.book Page 30 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR away from the battery and provide sufficient ventilation when charging it in an enclosed space. ● KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN. 2. If the battery will be stored for more than two months, check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary. 3. Fully charge the battery before installation. 4.
E_3bt.book Page 31 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR Specified fuses: Main fuse: Headlight fuse: Signaling system fuse: Ignition fuse: 30 A 15 A 15 A 15 A EC000103 CAUTION: Do not use a fuse of a higher amperage rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire. @ 1. 2. 3. 4. 5.
E_3bt.book Page 32 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Headlight coupler 2. Headlight bulb cover 1. Headlight bulb holder 1. Do not touch this area. 3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. 2. Disconnect the headlight coupler, and then remove the headlight unit and bulb cover. EW000119 WARNING Headlight bulbs get very hot.
E_3bt.book Page 33 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle 1. Screw (× 2) 1. Tail/brake light bulb (× 2) 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. EAU00855 Replacing a turn signal light bulb or the tail/brake light bulb 6 1.
E_3bt.book Page 34 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR To service the rear wheel Raise the rear wheel off the ground by using a motorcycle stand or, if a motorcycle stand is not available, by placing a jack either under each side of the frame in front of the rear wheel or under each side of the swingarm. 1. Speedometer cable EAU03239 1. Front wheel axle pinch bolt 2. Wheel axle Front wheel 2. Loosen the front wheel axle pinch bolt, then the wheel axle. 3.
E_3bt.book Page 35 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 5. Push down hard on the handlebar several times to check for proper fork operation. 6. Tighten the wheel axle to the specified torque. Tightening torque: Wheel axle: 58 Nm (5.8 m·kg) 1. Retainer EAU01394 6 To install the front wheel 1. Install the speedometer gear unit into the wheel hub so that the projections mesh with the slots. 2. Lift the wheel up between the fork legs.
E_3bt.book Page 36 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 6. Loosen the rear wheel axle pinch bolt, and then pull the wheel axle out. 7. Pull the wheel to the right to separate it from the final gear case, and then remove it. 1. 2. 3. 4. 5. 6. Rear wheel axle pinch bolt Brake pedal free play adjusting nut Brake rod Brake torque rod bolt/nut/cotter pin Brake torque rod Wheel axle 6 2.
E_3bt.book Page 37 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR 6. Lower the rear wheel so that it is on the ground. 7. Tighten the axle nut, pinch bolt and brake torque rod nut to the specified torques. Tightening torques: Axle nut: 107 Nm (10.7 m·kg) Rear wheel axle pinch bolt: 16 Nm (1.6 m·kg) Brake torque rod nut: 20 Nm (2.0 m·kg) EAU01406 6 To install the rear wheel 1.
E_3bt.book Page 38 Thursday, September 7, 2000 10:01 AM PERIODIC MAINTENANCE AND MINOR REPAIR EAU01562 Troubleshooting chart EW000125 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. @ @ 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. There is compression. Check the ignition. There is no compression. Have a Yamaha dealer check the vehicle. Check the fuel level in the fuel tank. The engine does not start.
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E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM MOTORCYCLE CARE AND STORAGE Care .................................................................................................. 7-1 Storage ..............................................................................................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM MOTORCYCLE CARE AND STORAGE EAU03412 7- Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM MOTORCYCLE CARE AND STORAGE Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM MOTORCYCLE CARE AND STORAGE 7 After cleaning 1. Dry the motorcycle with a chamois or an absorbing cloth. 2. Use a chrome polish to shine chrome, aluminum and stainlesssteel parts, including the exhaust system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.) 3.
E_3bt.book Page 4 Thursday, September 7, 2000 10:01 AM MOTORCYCLE CARE AND STORAGE Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA00014 @ @ CAUTION: ● Storing the motorcycle in a poorly ventilated room or covering it with a tarp, while it is still wet, will allow water and humidity to seep in and cause rust.
E_3bt.book Page 5 Thursday, September 7, 2000 10:01 AM MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground. Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot. 8.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM SPECIFICATIONS Specifications ..................................................................................... 8-1 Conversion table ................................................................................
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E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM SPECIFICATIONS Gear ratio Final gear oil Type Quantity Air filter 1st Hypoid gear oil SAE 80 (API GL4) or multigrade hypoid gear oil SAE 80W-90 0.19 L Dry type element Fuel Type Regular unleaded gasoline Fuel tank capacity 13.5 L Fuel reserve amount 2.5 L Manufacturer MIKUNI Model × quantity BDS34 × 2 NGK / BPR6ES or DENSO / W20EPR-U Gap 0.7–0.8 mm Primary reduction ratio 1.
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM SPECIFICATIONS Maximum load* 220 kg (except for A) Rear 218 kg (for A) Tire air pressure (measured on cold tires) Drum brake Operation Right foot Suspension Up to 90 kg* Front 200 kPa (2.00 kg/cm2, 2.00 bar) Rear 225 kPa (2.25 kg/cm2, 2.25 bar) Front 200 kPa (2.00 kg/cm2, 2.00 bar) Rear 250 kPa (2.50 kg/cm2, 2.
E_3bt.book Page 4 Thursday, September 7, 2000 10:01 AM SPECIFICATIONS Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Auxiliary light 12 V, 4 W × 1 (except for GB) 12V, 3.4 W × 1 (for GB) Tail/brake light 12 V, 5/21 W × 2 Front turn signal light 12 V, 21 W × 2 Rear turn signal light 12 V, 21 W × 2 Meter lighting 14 V, 3 W × 1 Neutral indicator light 14 V, 3 W × 1 High beam indicator light 12 V, 1.
E_3bt.book Page 5 Thursday, September 7, 2000 10:01 AM SPECIFICATIONS EAU01064 Conversion table CS-02E Conversion table All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Example METRIC MULTIPLIER METRIC TO IMPERIAL Metric unit IMPERIAL ** mm × 0.03937 = ** in 2 mm × 0.03937 = 0.08 in 8 8-5 Multiplier Imperial unit Torque m·kg m·kg cm·kg cm·kg 7.233 86.794 0.0723 0.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM CONSUMER INFORMATION Identification numbers ........................................................................ 9-1 Key identification number .................................................................. 9-1 Vehicle identification number ............................................................. 9-1 Model label.........................................................................................
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM CONSUMER INFORMATION EAU01039 9- EAU02944 Identification numbers Record the key identification number, vehicle identification number and model label information in the spaces provided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. 1. Key identification number 1. KEY IDENTIFICATION NUMBER: CA-02E 2.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM CONSUMER INFORMATION 1. Model label EAU01804 Model label The model label is affixed to the frame under the rider seat. (See page 3-7 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM INDEX 10- A E L Air filter element, cleaning ......................6-11 Engine break-in ....................................... 5-4 Engine oil and oil filter element ................ 6-7 Engine stop switch................................... 3-3 Light switch ..............................................3-3 B Battery ...................................................6-29 Brake and clutch levers, checking and lubricating ........................
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM INDEX Spark plugs, checking ............................. 6-5 Specifications .......................................... 8-1 Speedometer unit .................................... 3-2 Starter (choke) lever ................................ 3-6 Starting a cold engine .............................. 5-1 Starting a warm engine............................ 5-2 Start switch.............................................. 3-3 Steering, checking ....................
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OWNER’S MANUAL XV535 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2000 · 7 - 0.
