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Yamaha 1998 Virago 535 Owner's Manual

Contents

1. 1 1 Shift Dedalunsuss en 5 5 Front brake lever 5 6 LOCATION OF THE IMPORTANT Rear brake pedal 5 6 LABELS 2 1 Fuel tank Cap 5 6 Starter CHORE 5 7 DESCRIPTION vnlgo 3 1 Steering 1OCK irre tr DIO MS 5 7 Sob cio I E UM 5 8 MOTORCYCLE IDENTIFICATION 4 1 Helmet holder 5 9 Identification numbers record 4 1 Sidesta 5 10 Key identification number 4 1 Sidestand clutch switch Vehicle identification number 4 2 operation check 5 10 Model labe 4 2 PRE OPERATION CHECKS 6 1 CONTROL FUNCTIONS 5 1 Brakes o oes a 6 3 5 1 Front brake fluid leakage 6 4 Indicator Ig Es sioe pee tenent 5 2 CIUC ERIS 6 4 SDECCOMELEN codec a 5 3 Throttle OVID auc nici 6 5 Handlebar switches 5 3 ENGINE Oll eet t 6 5 Clutch disti Rose babe etc 5 5 Final gear oll 6 6 HEIC a 6 6 WliBelS 6 9 Accessories or replacement parts 6 10 Chassis fasteners 6 10 Lights signals and switches 6 10 Battery assueti ERU 6 11 FUG
2. 6 11 OPERATION AND IMPORTANT RIDING POINTS ip educi 7 1 Starting and warming up a cold engi NE 7 2 Starting a warm engine 7 5 7 5 To start out and accelerate 7 6 TO deceler lte 7 7 Recommended shift point 7 7 Engine break in eere 7 7 ml cca I I 7 8 PERIODIC MAINTENANCE AND MINOR REPAIR 8 1 PERIODIC MAINTENANCE 8 1 TOO Kits unes hat elt emen BZ PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM oem 8 3 General maintenance lubrication 8 5 Spark plug inspection 8 9 Canister for California only 8 10 8 11 Final gear oll secundes 8 14 PAVE 8 16 Carburetor adjustment 8 18 Valve clearance adjustment 8 18 Front brake lever free play 8 18 Rear brake pedal height and free play adjustment 8 19 Brake light switch adjustment 8 21 Checking the front brake pads and rear brake shoes 8 21 Inspecting the brake fluid level 8 22 Brake fluid replacement 8 23 Clutch lever free play adjustment 8 24 Cable inspection and lubrication 8 25 Throttle cable and grip lubrication 8 25 Brake and
3. Dear Yamaha ATV Owner Please Review this IMPORTANT SAFETY CARD before operating your ATV If card is not attached call 1 800 344 6418 Dear New Yamaha ATV Owner CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV You have purchased a quality Yamaha product that with proper use and care will provide hours of riding pleasure BEFORE YOU OPERATE YOUR NEW ATV Yamaha recommends these important points READ YOUR OWNER S MANUAL A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card to Yamaha today Name ATV Model Purchase Date READ CAREFULLY BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES EAA20201 INTRODUCTION Congratulations on your purchase of the Yamaha XV535 XV535S XV535C XV535SC This model is the result of
4. EUU32401 e Do not put in any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slip page e Be sure no foreign material enters the crankcase h Start the engine and warm up for a few minutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for the cause EAH45703 Final gear oil EUU63400 A WARNING Do not let foreign material enter the final gear case Be sure oil does not get on the tire or wheel 1 Oil level inspection a Place the motorcycle on a level place and hold it in an upright position The engine should be cool at ambient tem perature Remove the oil filler bolt and check the oil level The oil level should be at the brim of the hole Fill with oil as neces sary 3 Oil filler bolt 2 Correct oil level 1 Final gear oil 2 Gear oil replacement a Place an oil pan under the final gear case b Remove the oil filler bolt and the drain Oil capacity plug to drain the oil you Final gear case 0 19 L 0 17 Imp qt 0 20 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions EUUO2300 _ GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils 1 Drain plug may also be used c Reinstall and tighten the drain plug to the specified torque e Reinstall
5. Electrical Ignition system Generator system AC magneto generator Battery type voltage capacity GM12AZ 3A 12V 12AH Bulb voltage wattage x quantity Headlight Tail brake light Front flasher position light TCI 12V 65W 60W x 1 12V 8W 27W x 2 12V 27W 8W x 2 Rear flasher light 12V 27W x 2 Meter light 12V 3W x 1 Neutral indicator light 12V 3W x 1 High beam indicator light 12V 1 7W x 1 Turn indicator light 12V 3W x 1 10 4 EAL10100 CONSUMER INFORMATION EAL00900 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immediately inform the National Highway Traffic Safety Administra tion NHTSA in addition to notifying YAMAHA MOTOR CORP U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or YAMAHA MOTOR CORP U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transpor tation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline 1171 EALO00300 Motorcycle noise regulation TAMPERING WITH N
6. The troubleshooting chart describes a quick easy procedure for making checks _ If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your motorcycle Use only genuine Yamaha parts on your mo torcycle Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills EAJ50800 Troubleshooting chart EUU66300 Have tank cap A WARNING breather inspected Never check the fuel system for California only while smoking or in the vicinity fee bene b DE of an open flame kd pi ink pinch 1 Fuel Opentankcap ALS Start Fuel check No start to check internal Normal I fuel OK pressure Check canister hoses Go to compression check Go to ignition check Have engine inspected 2 Compression Normal resistance Unusually light or heavy resistance Replace spark plugs Compression check No start Turn over fuel OK engine 3 Ignition Ignition check Fuel OK Compression OK Go to battery check Engine turns fast battery is good 4 Battery Fuel OK No start Have engine Use electric starter No start inspected Battery check OE OK No start if applicable Engine turns slowly Have battery charged electrical problem a
7. each Yamaha motorcycle covered by this warranty with a displacement of 5Occ or greater that the vehi cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty 11 5 ENGINE DISPLACEMENT 5Occ to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 30 000 km 18 641 miles or five years whichever occurs first 280cc or over YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLO
8. switch wait a few seconds then try again Each attempt should be as short as possi ble to preserve the battery Do not crank the engine more than 10 seconds on any one attempt and 7 4 5 After starting the engine move the starter CHOKE back to the halfway position EUU02600 NOTE uu For maximum engine life always warm up the engine before starting off Never accel erate hard with a cold engine 6 After warming up the engine turn off the starter CHOKE completely EUUO3101 NOTE m e The engine is warm when it responds normally to the throttle with the start er turned off To avoid the possibility of excessive exhaust emissions never leave the starter circuit on longer than necessary The length of time the starter is needed depends upon the ambient temperature Warm ambient temperatures above 10 C bOF re quire about 7 seconds of starter use Cold ambient temperatures below 10 C 50 F require about 35 seconds with the starter turned on then about 2 5 minutes with the starter in the half way position e For maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine EAF 10802 Starting a warm engine The starter CHOKE is not required when the engine is warm EUU31401 See the Engine break in section prior to operating the motorcycle for the first time 7 5 EAF20003 Shifting The transmissio
9. EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse d Lack of proper maintenance e Accident or collision damage f Modification to original parts g Damage due to improper transportation SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspec tion and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of
10. IN THE OWNER S MANUAL 3 OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES 4 OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS SAFE RIDING 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predom inating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of acci dent Therefore a Wear a brightly colored jacket b Use extra caution when you approach and pass through intersections since inter sections are the most likely places for motorcycle accidents c Ride where other motorists can see you Avoid riding in another motorist s blind spot 4 Many accidents involve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle license a Make sure you are qualified Also only lend your motorcycle to experienced op erators b Know your skills and limits Staying within your limits may help you to avoid an accident c We recommend that you practice riding your motorcycle where there is no traffic until you have become thoro
11. Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It represents the high degree of craftsmanship and reli ability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic main tenance of this motorcycle If you have any questions about the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emissions standards for clean air applicable at the date of manufacture Yamaha has met these stan dards without reducing the motorcycle s performance or economy of operation To main tain these high standards it is important that you and your dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual EAA10700 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following nota tions AN 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 inspect ing or repairing the motorcycle 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 o
12. and acid corrosion may re sult 7 1 7 2 EAF18704 Starting and warming up a cold engine EUU02802 NOTE This motorcycle is equipped with an igni tion circuit cut off system 1 The engine can be started only under the following conditions a The transmission is in neutral b The sidestand is up the transmission is in gear and the clutch is disengaged 2 The motorcycle must not be ridden when the sidestand is down EUU69200 4A WARNING Before going through the following steps check the function of the sidestand switch and clutch switch Refer to page 5 10 TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN SIDESTAND IS UP PUSH THE START SWITCH PULL IN THE CLUTCH LEVER AND PUSH ENGINE WILL START THE START SWITCH ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN 1 Turn the main switch to ON and the engine stop switch to RUN 2 Shift the transmission into neutral EUU03001 When the transmission is in neutral the neutral indicator light should be on If the light does not come on ask a Yamaha dealer to inspect it 3 Turn on the starter CHOKE completely close the throttle grip 4 Start the engine by pushing the start switch EUU02501 NOTE ae ee If the engine fails to start release the start
13. area The ex haust fumes are poisonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has adequate ventilation 1 7 3 Always turn off the engine before leaving the motorcycle unattended and remove the ignition key When parking the motorcycle note the following a The engine and exhaust system may be hot Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas b Do not park the motorcycle on a slope or soft ground the motorcycle may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame The motorcycle could catch fire 4 When transporting the motorcycle in another vehicle be sure it is kept upright If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it off with soap and water and change your clothes EAA40000 LOCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operating this motorcycle A WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing YAMAHA 3MX 2118K 00 CA
14. clutch lever lubrication Lubricate the pivoting parts Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EAI31202 Sidestand lubrication Lubricate the sidestand pivoting and mat ing parts Check to see that the sidestand moves up and down smoothly Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EUU70401 A WARNING If the sidestand does not move smoothly consult a Yamaha dealer 8 26 EAI20502 Front fork inspection EUU65700 A WARNING Securely support the motorcycle so there is no danger of it falling over 1 Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork Operation check Place the motorcycle on a level place Hold the motorcycle in an upright po sition and apply the front brake Push down hard on the handlebars several times and check if the fork re bounds smoothly If any damage or unsmooth movement is found with the front fork consult a Yamaha dealer 8 27 EAI60301 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bear ings may be dangerous Place a stand un der the engine to raise the front wheel off the ground Hold the lower end of the front forks and try to move them forward and backward If any free play can be felt ask a Yamaha dealer to inspect and adjust the steering Inspection is easier if the fron
15. electrical circuits are switched on and the headlight meter light taillight and front position lights come on The engine can be started The key cannot be removed in this position EABOO600 OFF All electrical circuits are switched off The key can be removed in this position EABO4401 P Parking The taillight and front position light come on but all other circuits are off With the key at OFF push it into the main switch and release it Then turn it counterclock wise to P and remove it To cancel the parking turn the key clockwise EUU08800 NOT Ei es c Always turn the main switch to OFF and remove the key when the motorcycle is un attended EAB10000 Indicator lights 1 High beam indicator light HIGH BEAM 2 Neutral indicator light NEUTRAL 3 Turn indicator light TURN EAB 12403 Turn indicator light TURN This indicator flashes when the turn switch is moved to the left or right EAB10201 Neutral indicator light NEUTRAL This indicator comes on when the trans mission is in neutral EAB10301 High beam indicator light HIGH BEAM This indicator comes on when the head light high beam is used EAB40005 Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to 0 with the re set knob Use the trip odometer to esti mate how far you can ride on a tank of fu
16. engine with oil if necessary 6 5 8 11 8 14 Final gear oil e Check for leakage 6 5 8 14 8 15 Throttle e Check for smooth operation 6 5 8 25 6 3 w 6 4 8 18 8 23 Check fluid level fill with distilled water if necessary 6 11 8 28 8 30 Lights signals and f Wheels Tires e Check tire pressure wear damage and spoke tightness 6 6 6 9 Chassis fastoners Check the tightness of all chassis nuts bolts and screws 6 10 Adjust if necessary 6 1 NOTE Pre operation checks should be made each time the motorcycle is used Such an inspec tion can be thoroughly accomplished in a very short time and the added safety it assures is more than worth the time involved A WARNING 1 The engine exhaust pipes and mufflers will be very hot after the engine has been run Be careful not to touch them or to allow any clothing item to contact them dur ing inspection or repair 2 if any item in the PRE OPERATION CHECK is not working properly have it inspected and repaired before operating the motorcycle 6 2 EAE13303 Brakes 1 Brake lever and brake pedal Check for correct free play in the front brake lever and rear brake pedal and adjust if necessary See page 8 18 for details Make sure the brakes are working properly by checking at low speed shortly after starting out EUU62300 WARNING A soft spongy feeling in the brake lever in dicates a failure in the brake sys
17. indicate the presence of air in the brake system This air must be removed by bleeding the brake sys tem before the motorcycle is operat ed Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident Have a Yamaha dealer in spect and bleed the system if neces sary 8 19 EAH84503 Rear brake pedal height and free play ad justment EUU64301 It is advisable to have a Yamaha dealer make this adjustment 1 Pedal height a Loosen the locknut n BS Di gue c o ee Use 2 2 Locknut Sad v 1 Adjusting bolt b By turning the adjusting bolt clock 2 Free play wise or counterclockwise adjust the The rear brake pedal free play should brake pedal position as shown be adjusted to 20 30 mm 0 8 1 2 in at the brake pedal end Turn the ad justing nut on the brake rod in direc tion to reduce free play or in direction b to increase free play 1 Footrest 2 Pedal height 38 mm 1 5 in 3 Free play c Tighten the locknut EUU64400 A WARNING 1 Adjusting nut EUU64500 WARNING Check the operation of the brake light af ter adjusting the rear brake 8 20 After adjusting the pedal height adjust brake pedal free play EAH83302 Brake light switch adjustment The rear brake light switch is activated by the brake pedal and is properly adjusted when the bra
18. it piston and or cylinder wear may re sult 8 17 EUU78500 4 WARNING e Before reinstallation make sure that the fuel hoses are not damaged at all If any damage is found it may result in a fuel leak so do not start the en gine Ask a Yamaha dealer for repairs e Always make sure that the fuel hoses are properly connected in place and not pinched EAH93002 Carburetor adjustment The carburetors are important parts of the engine and emission control system Ad justing should be left to a Yamaha dealer with the professional knowledge special ized data and equipment to do so properly EAH90801 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional Yamaha service technician 80104 Front brake lever free play adjustment The free play at the front brake lever should be 2 5 mm 0 08 0 2 in 1 Loosen the locknut Q PNE D 262 1 Adjusting bolt 2 Locknut 8 18 9 Free play Turn the adjusting bolt in direction 8 to increase free play or in direction b to decrease free play 3 After adjusting tighten the locknut EUU81500 A WARNING e Check the brake lever free play Be sure the brake is working properly A soft or spongy feeling in the brake lever can
19. not operate it at one set throttle position 2 150 500 km 90 300 mi Avoid prolonged operation above 1 2 throttle Rev the motorcycle freely through the gears but do not use full throttle at any time 3 500 1 000 km 300 600 mi Avoid cruising speeds in excess of 3 4 throttle EUU31801 After 1 sure to replace the engine oil oil filter and final gear oil 4 1 000 km 600 mi and beyond Avoid prolonged full throttle opera tion Vary speed occasionally EUU32200 If any engine trouble should occur during the break in period consult a Yamaha dealer immediately 7 8 EAF40001 Parking When parking the motorcycle stop the en gine and remove the ignition key EUU63001 A WARNING The exhaust system is hot Park the mo torcycle in a place where pedestrians or children are not likely to touch the motor cycle Do not park the motorcycle on a slope or soft ground the motorcycle may overturn EAHO00000 PERIODIC MAINTENANCE AND MINOR REPAIR EAHO00101 Periodic inspection adjustment and lubri cation will keep your motorcycle in the saf est and most efficient condition possible Safety is an obligation of the motorcycle owner The most important points of mo torcycle inspection adjustment and lubri cation are explained in the following pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establish ment or indi
20. the switch to RUN to start the engine In case of emer gency turn the switch to OFF to stop the engine EAB60703 Start switch START The starter motor cranks the engine when pushing the start switch EUU30700 See starting instructions prior to starting the engine EAB62202 Fuel reserve switch FUEL This switch should usually be kept ON while riding If you run out of fuel while riding move the switch to RES and refu el at the first opportunity Then move the switch to ON EUU 12900 NOTE When the switch is turned to RES about 2 5 L 0 5 Imp gal 0 7 US gal remain in the fuel tank EAB70003 Clutch lever The clutch lever is located on the left han dlebar and the ignition circuit cut off sys tem is incorporated in the clutch lever holder Pull the clutch lever to the handle bar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer 5 5 to the engine starting procedures for a de scription of the ignition circuit cut off sys tem EAB80001 Shift pedal This motorcycle is equipped with a con stant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting N Neutral 1 Shift pedal EAB90001 Front brake lever The front brake lever is located on the right handlebar Pull it tow
21. 0 12 0 20 in at the throttle grip If the free play is incorrect ask a Yamaha dealer to make this adjust ment a Free play EAE40003 Engine oil Make sure the engine oil is at the specified level Fill with oil as necessary See page 8 11 for details Recommended oil 30 F 40 F 50 F 60 F YAMALUBE 4 20W40 or SAE 20W40 type SE motor oil YAMALUBE 4 10W30 _ 0 5 C 10 C 15 C SAE 10W30 type SE motor oil Recommended engine oil classification API Service SE SF type or equivalent e g SF SE SF SE CC SF SE SD etc Oil quantity Total amount 3 2 L 2 8 Imp qt 3 4 US at Periodic oil change 2 6 L 2 3 Imp qt 2 7 US at With oil filter replacement 2 8 L 2 5 Imp qt 3 0 US qt EAE40301 Final gear oil Make sure the final gear oil is at the speci fied level Fill with oil as necessary see page 8 14 for details Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions EUUO2300 NOTE n GL 4 is a quality and additive rating GL 5 or GL 6 rated hypoid gear oils may also be used 6 6 EAE96101 Tires To ensure maximum performance long service and safe operation note the fol lowing 1 Tire air pressure Always check and adjust the tire pres sure before operating the motorcycle EUU67500 A WARNING Tire inflation pressure s
22. AHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty n addition Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable Y E S is designed and administered by Yamaha Motor expenses you incur because your Yamaha needs Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purcha
23. F20302 To decelerate 1 Apply both the front and the rear brakes at the same time to slow the motorcycle 2 When the motorcycle reaches 20 km h 12 4 mi h shift into first gear Any time the engine is about to stall or runs very roughly pull in the clutch and use the brakes to stop 3 When the motorcycle is almost com pletely stopped shift into neutral The neutral indicator light should come on EAF20500 Recommended shift point Deceleration shift point km h mi h 20 12 5 20 12 5 20 12 5 20 12 5 Acceleration shift point km h mi h 151 2nd 2nd 3rd 3rd 4th 4th 5th 16 9 9 24 14 9 32 19 9 40 24 9 EAF30000 Engine break in There is never a more important period in the life of your motorcycle than the period between zero and 1 000 km 600 mi For this reason we ask that you carefully read the following material Because the engine is brand new you must not put an exces sive load on it for the first 1 000 km 600 mi The various parts in the engine wear and polish themselves to the correct oper ating clearances During this period pro longed full throttle operation or any condition which might result in excessive heating of the engine must be avoided EAF31802 1 0 150 km 0 90 mi Avoid operation above 1 3 throttle Stop the engine and let it cool for 5 to 10 minutes after every hour of opera tion Vary the speed of the motorcycle from time to time Do
24. OISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or render ing inoperative by any person other than for purposes of maintenance repair or replace ment of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or ren dered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LIST ED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 11 2 EALO00501 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to document that maintenance has been completed in accordance with the emission warran ty The chart below is printed only as a reminder to you that the maintenance work is re quired It is not acceptable proof of maintenance work MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE csi NAME AND ADDRESS iE 1 000km 600mi or 1 mo 7 000km 4 400mi or 7 mos 13 000km 8 200mi or 13 mos 19 000km 12 000mi or 19 mos 25 000km 15 800mi or 25 mos DATE OF SERVICING DEALE
25. R SERVICE MILEAGE NAME AND ADDRESS REMARKS MAINTENANCE INTERVAL 31 000km 19 600mi or 31 mos 37 000km 23 400mi or 37 mos 43 000km 27 200mi or A3 mos 49 000km 31 000mi or 49 mos 55 000km 34 800mi or 55 mos 61 000km 38 600mi or 61 mos 11 4 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants each new street or enduro model Yamaha motorcycle purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the pro duct s warranty period All parts replaced under war ranty become property of Yamaha Motor Corporation U S A GENERAL
26. UTION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint If electrolyte spills wash area with fresh water immediately Be sure to connect breather hose after installing battery YAMAHA 3JL 28177 00 California only EMISSION HOSE ROUTING FROM CARB FUEL TANK CANISTER TO ATMOSPHERE YAMAHA MOTOR CO LTD 2 2 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 200 kPa 2 00 kgf cm 29 psi REAR 225 kPa 2 25 kgf cm 33 psi e 90 kg 198 Ibs maximum load FRONT 200 kPa 2 00 kgf cm 29 psi REAR 250 kPa 2 50 kgf cm 36 psi 3BT 21668 00 EAA50001 DESCRIPTION Right view Left view D o amp qw 5 D 12 Qo E A c 4S 3 Ara e N 29 h e GB iN AS EN RUN A SiG BY eR D D 9 DT d 00 Controls Instruments 1 Rear flasher light 13 Helmet holder 2 Rear shock absorber 14 Passenger seat 19 QU QU 3 Fuel tank 15 Tail brake light ASS c 4 Sub fuel tank 16 Main switch e E ws 5 Front flasher position 17 Shift pedal SS AB light 18 Front wheel p j vizi A 9 6 Front fender 19 Clutch lever ISSUE 7 Brake pedal 20 Speedometer 8 Footrest 21 Brake lever 9 Muffler 22 Throttle grip QU 29 2 10 Rear wheel 23 Right handlebar switch 11 Headlight 24 Left handlebar switch 12 Rider
27. W THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damage and oil oil filters air filters spark plugs and brake shoes or pads What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle use operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transporation and or tie down and so on If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Ow
28. XV535SC 483 Ib 219 kg When loading within these weight limits keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability 2 Shifting weights can create a sudden imbalance Make sure that accessories and car go are securely attached to the motorcycle before riding Recheck accessory mounts and cargo restraints frequently 1 5 3 Never attach any large or heavy items to the handlebars front forks or front fender These items including such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response ACCESSORIES Genuine Yamaha accessories have been specifically designed for use on this motorcy cle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories You should use extreme caution when selecting and installing any acces sories Keep in mind these guidelines for mounting accessories in addition to those provided under LOADING 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Carefully inspect the accessory before using it to make sure it does not in any way reduce ground clearance or cornering clearance limit suspension travel st
29. able DOT 3 can be used Refill with the same type of brake flu id Mixing fluids may result in a harm ful chemical reaction and lead to poor brake performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boil ing point of the fluid and may result in vapor lock Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately Have a Yamaha dealer check the cause if the brake fluid level goes down 8 23 1 Minimum level mark LOWER EAH83501 Brake fluid replacement 1 a Complete fluid replacement should be done only by trained Yamaha service personnel Have a Yamaha dealer replace the fol lowing components during periodic maintenance or when they are dam aged or leaking Replace all rubber seals every two years b Replace all hoses every four years EAI00505 Clutch lever free play adjustment The clutch lever free play should be adjust ed to 10 15 mm 0 39 0 59 in 1 Loosen the locknut at the clutch lever 1 Locknut 2 Adjusting bolt 3 Free play 2 Turn the adjusting bolt at the clutch le ver in direction 8 to increase free play or in direction to decrease free play Tighten the locknut at the clutch lever 8 24 If the specified free play cannot be ob tained proceed with the following steps Loosen the locknut at the clutch lever Turn the adjust
30. and tighten the oil filler bolt to the specified torque Tightening torque Drain plug 23 Nm 2 3 m kg 17 ft Ib Tightening torque Oil filler bolt 23 Nm 2 3 m kg 17 ft lb d Fill the gear case to the brim of the f After replacement of the final gear oil hole with recommended oil be sure to check for oil leaks 8 15 EAH65503 Air filter The air filter should be cleaned at the spec ified intervals It should be cleaned more frequently if you are riding in unusually wet or dusty areas 1 Remove the seats 2 Remove the sub fuel tank holding bolts Ay SS LTO 222 3 Lift the front of the sub fuel tank up ward and position it away from the air filter Do not remove it EUU78401 A WARNING e Support the sub fuel tank carefully during this procedure e Do not tilt the sub fuel tank too much or pull it too hard as the fuel hose con nections may become loose and fuel leakage may result 4 Remove the air filter case by removing the screw 7 Reassemble by reversing the removal procedure EUU42402 1 Air filter case screw 5 Pull out the air filter 6 Tap the air filter lightly to remove e Make sure the air filter is properly most of the dust and dirt Blow out the seated in the filter case remaining dirt with compressed air as e The engine should never be run with shown If the air filter is damaged re out the air filter installed Excessive place
31. ard the handlebar to apply the front brake EAB90101 Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake EACO0101 Fuel tank cap TO OPEN Insert the key and turn it 1 4 turn clockwise The lock will be released and the cap can be opened 5 6 1 Open TO CLOSE Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original position EUUO1200 NOTE 2 This tank cap cannot be closed unless the key is in the lock The key cannot be re moved if the cap is not locked properly EUU61100 A WARNING Be sure the cap is properly installed and locked in place before riding the motorcycle EAC20502 Starter CHOKE Starting a cold engine requires a richer air fuel mixture A separate starter circuit sup plies this mixture Move in direction to turn on the starter Move in direction B to turn off the starter 1 Starter CHOKE EAC30201 Steering lock To lock the steering turn the handlebars all the way to the right Open the steering lock cover turn the key 1 8 counterclock wise then push the key in and turn it 1 8 turn clockwise After checking to see that the steering is locked remove the key from the lock and close the cover To release the lock reverse the above procedure 1 Steering lock EAC43400 Seat 2 Rider seat 1 Passe
32. ck Front fork oil operation and leakage Sidestand pivot 1 000 km 600 mi 1 7 000 km 4 400 mi or TYPE Yamaha chain and cable lube or SAE 10W30 motor oil Molybdenum disulfide grease Yamaha chain and cable lube or SAE 10W30 motor oil Yamaha chain and cable lube or SAE 10W30 motor oil Yamaha chain and cable lube or SAE 10W30 motor oil 8 6 ODOMETER READINGS 2 13 000 km 8 200 mi ODOMETER READINGS 2 INITIAL HEF uu Check bearing assembly for looseness Moderately repack every 24 000 km 15 200 mi Check bearing for smooth rotation Check specific gravity and breather pipe for proper operation Check and clean or replace if necessary 1 000 km 7 000 km 13 000 km 600 mi 4 400 mi 8 200 mi or or 1 month 7 months Lithium soap base grease Steering bearings Wheel bearings Battery Sidestand switch Items marked with an asterisk require special tools data and technical skills for servicing Take the motorcycle to a Yamaha Dealer or refer to the Service Manual when servicing these items 8 7 NOTE e e For farther odometer reading repeat the above maintenance at the period estab lished 1 Every 6 000 km 3 800 mi 2 Every 12 000 km 7 600 mi and 3 Every 24 000 km 15 200 mi intervals e Brake fluid replacement 1 When disass
33. could contribute to an impairment of vision which could delay seeing a hazard 3 The use of heavy boots jacket trousers gloves etc is effective in preventing or re ducing abrasions or lacerations 4 Never wear loose fitting clothing It could catch on the control levers footrests or wheels and cause injury or accident 5 Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions MODIFICATION Modifications made to the motorcycle not approved by Yamaha or the removal of orig inal equipment may render your motorcycle unsafe for use and may cause severe per sonal injury Modifications may also make your motorcycle illegal to use 1 4 LOADING AND ACCESSORIES Adding accessories or cargo to your motorcycle can adversely affect stability and han dling if the weight distribution of the machine is changed To avoid the possibility of an accident extreme caution should be used if adding cargo or accessories to your motor cycle Use extra care if riding a motorcycle which has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding accessories to your mo torcycle The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of XV535 XV535S 485 Ib 220 kg XV535C
34. eering travel or control operation or obscure lights or reflectors a Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum 1 6 b Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects Wind may attempt to lift the motorcycle or the motorcy cle may become unstable in cross winds These accessories may also cause insta bility when being passed by or passing large vehicles c Certain accessories can displace the operator from his or her normal riding posi tion This improper position limits the freedom of movement of the operator and may limit control ability Therefore such accessories are not recommended 2 Caution must be used if adding electrical accessories If these accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power GASOLINE AND EXHAUST GAS 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn off the engine when refueling b Take care not to spill any gasoline on the engine or exhaust system when refuel ing c Never refuel while smoking or in the vicinity of an open flame 2 Never start the engine or let it run for any length of time in a closed
35. el This information will enable you to plan fuel stops in the future 2 Odometer 1 Reset knob 3 rip odometer 5 3 EAB60000 Handlebar switches 1 Dimmer switch 4 Engine stop switch LIGHTS ENGINE STOP 2 Turn signal switch 5 Fuel reserve switch TURN FUEL 3 Horn switch HORN 6 Start switch START EAB60101 Dimmer switch LIGHTS Turn the switch to HI for the high beam and to LO for the low beam EAB60301 Turn signal switch TURN This model is equipped with self cancel ling 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 released it will return to the center position To cancel the signal push the switch in after it has returned to the center position If the switch is not can celled by hand it will self cancel after the motorcycle has travelled for about 15 sec onds or approximately 150 m 490 ft whichever is greater The self cancelling mechanism only operates when the mo torcycle is moving Therefore the signal will not self cancel while you are stopped at an intersection EAB60201 Horn switch HORN Press the switch to sound the horn 5 4 EAB60902 Engine stop switch ENGINE STOP The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system Turn
36. embling the master cylinder or caliper cylinder replace the brake flu id Normally check the brake fluid level and add fluid as required 2 Onthe inner parts of the master cylinder and caliper cylinder replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged 8 8 EAH20102 Spark plug inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine Normally all spark plugs from the same engine should have the same color on the white insulator around the center elec trode The ideal color at this point is a me dium to light tan color for a motorcycle that is being ridden normally If one spark plug shows a distinctly different color there could be something wrong with the engine Do not attempt to diagnose such problems yourself Instead take the motorcycle to a Yamaha dealer You should periodically remove and inspect the spark plugs be cause heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion becomes exces 8 9 sive or if carbon and other deposits are ex cessive you should replace the spark plug with the specified plug Specified spark plug BP7ES NGK or W22EP U DENSO Before installing any spark plug measure the electrode gap with a wire thickness gauge Adjust the gap to specification 1 Spark plug gap Spark plu
37. er lu XE T del Twat PRY 2 Head 5 Spare fuse x 2 ca 1 Main fuse 3 Signal 4 Ignition EUU34400 Do not use fuses of higher amperage rat ing than those recommended Substitu tion of a fuse of improper rating can cause extensive electrical system damage and possibly a fire Specified fuse Main Head 1 Holding screw x 2 Signal 2 Disconnect the headlight connector Ignition and remove the bulb holder cover EAI83502 Replacing the headlight bulb If the headlight bulb burns out replace the bulb as follows 1 Remove the headlight unit assembly 8 31 1 Headlight connector 2 Bulb holder cover 3 Turn the bulb holder counterclockwise and remove the defective bulb 1 Bulb holder EUU66001 A WARNING Keep flammable products and your hands away from the bulb while it is on as it Is hot Do not touch the bulb until it cools down 8 32 Put a new bulb into position and se cure it in place with the bulb holder Install the bulb holder cover Reconnect the headlight connector Install the headlight unit assembly If the headlight beam adjustment is nec essary ask a Yamaha dealer to make adjustment EAJ50002 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during opera tion Any problem in the fuel compression or ignition systems can cause poor starting and loss of power
38. f a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the side wall is cracked contact a Yamaha dealer immediately and have the tire re placed 1 Tread depth 2 Side wall 3 Wear indicator 6 8 FRONT 3 00 19 495 L303A Dunlop 3 00 19 495 F14G REAR 140 90 15 705 G508 Dunlop 140 90 15 705 K425 Minimum tire tread depth 1 0 mm 0 04 in front and rear EUU73000 A WARNING For safe operation when tires are re placed they must be replaced with the recommended tire Other rubber com pounds tread patterns tube type tires or different ply rate tires may result in tire failure and or motorcycle instability EUU68402 7 WARNING It is dangerous to ride with a worn out tire When a tire tread begins to show lines have a Yamaha dealer re place the tire immediately Brakes tires and related wheel parts replace ment should also be left to a Yamaha dealer Patching a punctured tube is not rec ommended If it is absolutely neces sary to do so use great care and replace the tube as soon as possible with a good quality replacement 6 9 EAE93401 Wheels To ensure maximum performance long service and safe operation note the fol lowing 1 Always inspect the wheels before a ride Check for cracks bends or warpage of the wheel Be sure the spokes are tight and unda
39. g gap 0 7 0 8 mm 0 028 0 031 in When installing the spark plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and tighten the spark plug to the specified torque Tightening torque Spark plug 20 Nm 2 0 m kg 14 0 ft lb EUU03802 NOTE o e er e If a torque wrench is not available when you are installing a spark plug a good esti mate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tight ened to the specified torque as soon as possible 8 10 EAH92600 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before using this motor cycle be sure to check the following 1 Check each hose connection 2 Check each hose and canister for cracks or damage Replace if dam aged Make sure the canister breather is not blocked Clean it if necessary EMISSION HOSE ROUTING From fuel tank Carburetor Canister To atmosphere EAH46902 Engine oil 1 Oil level inspection a Place the motorcycle on a level place and hold it in an upright position Warm up the engine for several min utes EUU03901 NOTE ence e Be sure the motorcycle is positioned straight up when checking the oil level A slight tilt toward the side can result in false readings b With the engine stopped check the oil level through the level window locat ed at the lower par
40. gear oil Capacity 0 19 L 0 17 Imp qt 0 20 US qt Fuel Type UNLEADED FUEL Tank capacity 13 5 L 3 0 Imp gal 3 6 US gal Reserve amount 2 5 L 0 5 Imp gal 0 7 US gal Carburetor Type quantity Manufacturer BDS34 2 MIKUNI Spark plug Type manufacturer Gap BP7ES NGK or W22EP U DENSO 0 7 0 8 mm 0 028 0 031 in Wet multi disc Clutch type 10 2 Transmission Primary reduction system Spur gear Primary reduction ratio 70 36 1 944 Secondary reduction system Shaft drive 19 18 x 32 11 3 071 Constant mesh 5 speed Secondary reduction ratio Transmission type Operation Left foot operation Gear ratio 1st 38 14 2 714 2nd 38 20 1 900 3rd 35 24 1 458 4th 28 24 1 166 5th 29 30 0 966 Chassis Frame type Caster angle Trail Tire Type Size Front Rear Pressed backbone 31 5 125 mm 4 92 in With tube 3 00 19 49S 140 90 15 705 Front brake type Single Disc brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation 10 3 Suspension Front Rear Telescopic fork Swingarm Shock absorber Front Rear Coil spring Oil damper Coil spring Oil damper Wheel travel Front Rear 150 mm 5 9 in 85 mm 3 3 in
41. hase If a question or problem arises regarding warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model engine serial number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name engine serial number dealer number or dealer s name as it is shown on your warranty identification your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A WARRANTY DEPARTMENT P O Box 6555 Cypress California 90630 This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law YAM
42. heck the tightness of all chassis nuts bolts and screws before a ride Take the motorcycle to a Yamaha dealer or refer to the Service Manual for correct tighten ing torque EAE71500 Lights signals and switches Check all the lights meter lights and indi cator lights to make sure they are in work ing condition Check the operation of the handlebar switches and main switch EAE70502 Battery Check the fluid level and fill if necessary Use only distilled water if refilling is neces sary See page 8 28 for details EAE80000 Fuel Make sure there ts sufficient fuel in the tank EUU61000 44 WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may over flow when the fuel heats up later and ex pands 6 11 1 Filler tube 2 Fuel level EUU39302 Always wipe off spilled fuel immediately with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic parts EAE81701 Recommended fuel UNLEADED FUEL Fuel tank capacity Total 13 5 L 3 0 Imp gal 3 6 US gal Reserve 2 5 L 0 5 Imp gal 0 7 US gal Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premiu
43. hould be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire inflation pressure must be adjusted according to total weight of cargo rider passenger and accessories fairing sad dlebags etc if approved for this model and vehicle speed 220 kg 485 Ib XV535 XV535S 219 kg 483 Ib XV535C XV535SC Maximum load 200 kPa 2 00 kgf cm 2 50 kgf cm 29 psi 36 psi Load is the total weight of cargo rider passenger and accessories 90 kg 198 Ibs load 250 kPa Maximum load 200 kPa 225 kPa Up to 90 kg 198 Ibs 2 00 kgf cm 2 25 kgf cm 29 psi 33 psi 6 7 EUU71001 44 WARNING Proper loading of your motorcycle is im portant for several characteristics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Se curely pack your heaviest items close to the center of the motorcycle and distrib ute the weight evenly from side to side Check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure the total weight of the cargo rider passenger and accessories fairing saddlebags etc if approved for this model does not exceed the maxi mum load of the motorcycle Operation of an overloaded motorcycle could cause tire damage an accident or even injury 2 Tire inspection Always check the tires before operat ing the motorcycle I
44. ing bolt at the clutch le ver in direction 8 to loosen the cable Loosen the locknut at the crankcase side aN 5 1 Locknut 7 Turn the adjusting nut at the crank case in direction to increase free play or in direction b to decrease free play 2 Adjusting nut 8 Tighten the locknut at the crankcase and the clutch lever EAI10101 Cable inspection and lubrication EUU64601 A WARNING Damage to the outer housing of cables may allow internal rusting and cause in terference with cable movement Replace damaged cables as soon as possible to prevent unsafe conditions Lubricate the inner cable and the cable end If it does not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil 8 25 EAI10201 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubri cated since the grip must be removed to get at the end of the throttle cable After re moving the screws hold the end of the ca ble up in the air and put in several drops of lubricant With the throttle grip disassem bled coat the metal surface of the grip as sembly with a suitable all purpose grease EAI30202 Brake and shift pedal lubrication Lubricate the pivoting parts Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EAI30301 Brake and
45. ke light comes on just before braking takes effect To adjust the rear brake light switch hold the switch body so it does not rotate while turning the adjust ing nut Turn the adjusting nut in direction 8 to make the brake light come on earlier Turn the adjusting nut in direction to make the brake light come on later 1 Main body 2 Adjusting nut 8 21 EAH81402 Checking the front brake pads and rear brake shoes EAH87401 FRONT Apply the brake and inspect the wear indi cator If the brake pads are worn to the wear limit have a Yamaha dealer replace the pads a Wear limit 0 8 mm 0 03 in 1 Wear indicator EAH82601 REAR Apply the brake and inspect the wear indi cator If the indicator reaches the wear limit line ask a Yamaha dealer to replace the shoes 2 Wear indicator 1 Wear limit 8 22 EAH88203 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level and fill when necessary Observe these precautions 1 When checking the fluid level make sure the top of the master cylinder is level by turning the handlebars Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake performance Recommended brake fluid DOT 4 EUU13100 INO TG ee e lf DOT 4 is not avail
46. m un leaded fuel Unleaded fuel will give you longer spark plug life and reduced mainte nance cost If unleaded gasoline is not available then leaded regular gasoline can be used 6 12 Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or vehicle per formance problems EAF00000 OPERATION AND 3 Before starting out always be sure IMPORTANT RIDING the sidestand is up Failure to retract POINTS the sidestand completely can result in a serious accident when you try to turn a corner 1 Before riding this motorcycle become thoroughly familiar with all operating controls and their functions Consult a Yamaha dealer regarding any control or function that you do not thorough ly understand 2 Never start your engine or let it run for any length of time in a closed area The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time Always op erate your motorcycle in an area with adequate ventilation 1 Be careful where you store personal items on the motorcycle Avoid block ing the air cleaner intake or perfor mance will suffer 2 Be careful not to put anything near the battery and its terminals Electri cal failure
47. maged If any abnormal condition exists in a wheel consult a Yamaha dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced Tires and wheels should be balanced whenever either one is changed or re placed Failure to have a wheel bal anced can result in poor performance adverse handling characteristics and shortened tire life Ride at moderate speeds after chang ing a tire since the tire surface must first be broken in for it to develop its optimal characteristics EAE93900 Accessories or replacement parts EUU69700 A WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your motorcycle should be de signed specifically for it and they must be securely mounted to maintain the inher ent stability of the original design Genu ine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genuine Yamaha Parts and Accessories before making an accessory purchase Use of non Yamaha approved parts or acces sories may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of parts or accessories manufactured by other companies Yamaha cannot be held liable for any con 6 10 sequences caused by the use of items which have not been approved by Yamaha EAE85101 Chassis fasteners Always c
48. n lets you control the amount of power you have available at a given speed for starting accelerating climbing hills etc The use of the shift ped al is shown in the illustration Page 5 5 To shift into neutral depress the shift ped al repeatedly until it reaches the end of its travel then raise the pedal slightly 1 2 EUU31501 Do not coast for long periods with the engine off and do not tow the motor cycle a long distance Even with gears in neutral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission Always use the clutch when changing gears The engine transmission and driveline are not designed to with stand the shock of forced shifting and can be damaged by shifting without using the clutch 7 6 EAF20101 To start out and accelerate 1 Pull the clutch lever to disengage the clutch Shift into first gear The neutral indica tor light should go out Open the throttle gradually and at the same time release the clutch lever slowly At the recommended shift point in the table below close the throttle and at the same time quickly pull in the clutch lever Shift into second gear Be careful not to shift into neutral Open the throttle part way and gradu ally release the clutch lever Follow the same procedure when shifting to the next higher gear Al ways shift gears at the recommended shift points EA
49. nd system inspected 8 34 EAKO00000 CLEANING AND STORAGE EAK02301 A CLEANING Frequent thorough cleaning of your mo torcycle will not only enhance its appear ance but will improve its general performance and extend the useful life of many components 1 Before cleaning the motorcycle a Block off the end of the exhaust pipes to prevent water entry a plastic bag and strong rubber band may be used b Make sure the spark plugs and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pres sure to do the job 9 1 EUU34602 Excessive hose pressure may cause water seepage and deterioration of wheel bear ings front fork brakes transmission seals and electrical parts Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 After riding on salted roads wash the motorcycle with cold water immedi ately Do not use warm water as it in creases the chemical reaction of the salt 5 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush ts handy for hard to get at plac es 6 Rinse the motorcycle off immediately with clean water and dry all su
50. ner s and Service Manual We do recommend however that items requiring special tools or equipment be done by a Yamaha motorcycle dealer Will the warranty be void or cancelled if do not operate or maintain my new motorcycle exactly as specified in the Owner s Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satisfa tion at the time of sale and upon your request at any later date In addition each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcycle dealer for the warranty coverage to remain effective 11 6 CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha motorcycle dealer within the continental United States Be sure to bring your warranty registration identification or other valid proof of the original date of purc
51. nger seat a Remove the passenger seat To open the seat lock insert the key in b Remove the two bolts and remove the the lock and turn it clockwise rider seat Then remove the seat When reinstall ing the seat insert the lobe on the rear of the seat into the receptacle on the frame then push down the seat 1 Open 5 8 c When reinstalling the seat insert the lobes on the front of the seat into the receptacles on the frame then tighten the bolts d Reinstall the passenger seat EUUO1700 NOTE Make sure that the seat is securely fitted 5 9 EAC50001 Helmet holder To open the helmet holder insert the key in the lock and turn it as shown To lock the helmet holder replace the holder in its original position EUU72900 44 WARNING Never ride with a helmet in the helmet holder The helmet may hit objects caus ing loss of control and possibly an acci dent 1 Open EAD30101 Sidestand This model is equipped with an ignition circuit cut off system The motorcycle must not be ridden when the sidestand is down The sidestand is located on the left side of the frame Refer to page 7 2 for an explanation of this system EUU68901 A WARNING This motorcycle must not be operated with the sidestand in the down position If the stand is not properly retracted it could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha has designed into this moto
52. o this motorcycle not ap proved by Yamaha may cause loss of per formance excessive emissions and render it unsafe for use Consult a Yamaha dealer before attempting any changes PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM ITEM ROUTINE Check and adjust valve clearance when engine is cold Check condition Adjust gap and clean Replace at 13 000 km 8 200 mi or 13 months and thereafter every 12 000 km 7 600 mi or 12 months INITIAL ODOMETER READINGS 3 1 2 1 000 km 7 000 km 13 000 km 600 mi 4 400 mi 8 200 mi or or Valve clearance Spark plug Check ventilation hose for cracks or damage Replace if necessary Check fuel hose and vacuum pipe for cracks or damage Replace if necessary Crankcase ventilation system Check for leakage Retighten if necessary s Replace gasket s if necessary Carburetor Adjust synchronization of Synchronization carburetors Check and adjust engine idle 7 Idle speed speed Adjust cable free play Exhaust system 8 3 INITIAL ODOMETER READINGS 3 1 2 ROUTINE 1 000 km 7 000 km 13 000 km 600 mi 4 400 mi 8 200 mi or or Check control system for emission control damage ein Replace if necessary It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic California t
53. r 7 Remove the battery and fully charge it Store it in a cool dry place and com pletely recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 30 F or more than 30 C 90 F See page 8 30 for battery storage precau tions EUU05800 o Make any necessary repairs before storing the motorcycle 9 3 EAL10300 SPECIFICATIONS XV535 XV535S XV535C XV535SC Dimension Overall length 2 225 mm 87 6 in Overall width 780 mm 30 7 in Overall height 1 120 mm 44 1 in Seat height 720 mm 28 3 in Wheel base 1 520 mm 59 8 in 160 mm 6 3 in 2 900 mm 114 2 in Minimum ground clearance Minimum turning radius Basic weight With oil and full fuel tank XV535 XV535S 195 kg 430 Ib XV535C XV535SC 196 kg 432 Ib Engine Type Air cooled 4 stroke gasoline SOHC Cylinder arrangement V2 cylinder Displacement 535 cm Bore x Stroke 76 0 x 59 0 mm 3 0 x 2 3 in Compression ratio 9 0 1 Starting system Electric starter Lubrication system Wet sump 10 1 Engine oil 4 cycle Type Capacity Periodic oil change With oil filter replacement Total amount See page 6 5 2 6 L 2 3 Imp qt 2 7 US qt 2 8 L 2 5 Imp qt 3 0 US qt 3 2 L 2 8 Imp qt 3 4 US qt Final gear oil Type SAE 80 API GL 4 Hypoid
54. r clear er EUU00001 NOTE e This manual should be considered a permanent part of this motorcycle and should re main with it even if the motorcycle is subsequently sold e 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 man ual If there is any question concerning this manual please consult your Yamaha dealer EUU60001 A WARNING PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATIS FACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR IN SPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE AFFIX DEALER LABEL HERE EAA00000 XV535K XV535SK XV535KC XV535SKC OWNER S MANUAL 1997 by Yamaha Motor Corporation U S A 1st Edition April 1997 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 10 71 EAA30001 CONTENTS SAFETY INFORMATION
55. rcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction re turn the motorcycle to a Yamaha dealer immediately for repair EAD30802 Sidestand clutch switch operation check Check the operation of the sidestand switch and clutch switch against the infor mation below TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH THE START SWITCH ENGINE WILL START CLUTCH SWITCH IS OK SIDESTAND IS DOWN ENGINE WILL STALL SIDESTAND SWITCH IS OK EUU69100 WARNING If improper operation is noted consult a Yamaha dealer immediately 5 11 EAE00001 PRE OPERATION CHECKS Owners are personally responsible for their vehicle s condition Your motorcycle s 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 thor ough visual inspection you check the following points before each ride TEM ROUINE PAGE komen free ply eid e ard tape cuten 64824 825 Engine oil e Check engine oil level fill
56. rfaces with a chamois clean towel or soft absorbent cloth 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive type wax may be applied to all painted and chrome plated sur faces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes EAK02404 B STORAGE Long term storage 60 days or more of your motorcycle will require some preven tive procedures to guard against deteriora tion After thoroughly cleaning the motorcycle prepare for storage as follows 9 2 1 Fill the fuel tank with fuel and add fuel stabilizer if available 2 Remove the spark plugs pour about one tablespoon of SAE 10W30 or 20W40 motor oil in each spark plug hole and reinstall the spark plugs Turn the engine over several times ground spark plug leads to coat the cylinder walls with oil EUU66400 A WARNING When using the starter motor to crank the engine remove the spark plug wires and ground them to prevent sparking 3 Lubricate all control cables 4 Block up the frame to raise both wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlets to prevent moisture from en tering 6 If storing in a humid or salt air atmo sphere coat all exposed metal surfac es with a light film of oil Do not apply oil to any rubber parts or the seat cov e
57. se Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage is honored at any authorized Yamaha dealer nationwide Y E S coverage is transferrable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your engine number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 714 761 7631 Y YAMAHA EXTENDED SERVICE
58. seat EAA60000 EAA61400 MOTORCYCLE Key identification number IDENTIFICATION The key identification number is stamped on the key Record this number in the 61800 space provided and use it for reference when obtaining a new key Identification numbers record Record the key identification number ve hicle identification number and model la bel information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER __ 2 VEHICLE IDENTIFICATION NUMBER 1 Key identification number 3 MODEL LABEL INFORMATION 4 1 EAA80000 Vehicle identification number The vehicle identification number stamped into the steering head pipe is 1 Vehicle identification number EUU00400 NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state 4 2 EAA61602 Model label The model label is affixed to the location shown in the figure Record the informa tion on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer 1 Model label CONTROL FUNCTIONS EABO0100 Main switch The main switch controls the ignition and lighting systems Its operation is described below 5 1 EAB04800 ON All
59. shift pedal lubrication 8 25 Brake and clutch lever lubrication 8 26 Sidestand lubrication 8 26 Front fork inspection 8 26 Steering inspection 8 27 Wheel bearings 8 28 Battery 8 28 Fuse replacement 8 30 Replacing the headlight bulb 8 31 Troubleshooting 8 33 Troubleshooting charrt 8 34 CLEANING AND STORAGE 9 1 A Cleaning eene 9 1 self EQ o S 9 2 SPECIFICATIONS 10 1 CONSUMER INFORMATION 11 1 Reporting safety defects 11 1 Motorcycle noise regulation 11 2 MAINTENANCE RECORD 11 3 Stereet and enduro motorcycle limited warranty 11 5 Yamaha extended service 11 7 EUU75602 SAFETY INFORMATION TWO WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING HE OR SHE SHOULD 1 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL AS PECTS OF MOTORCYCLE OPERATION 2 OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS
60. t wheel is removed EUU65700 WARNING Securely support the motorcycle so there is no danger of it falling over EAI60103 Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smooth ly have a Yamaha dealer inspect the wheel bearings The wheel bearings should be inspected according to the Gen eral Maintenance Schedule EAI70304 Battery Check the level of the battery electrolyte and make sure that the terminals are tight Fill with distilled water if the electrolyte level is low 8 28 Battery Route inside Pass through the clamp Route inside the bracket EUU33601 When inspecting the battery be sure the breather pipe is routed correctly If the breather pipe is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cos metic damage to the motorcycle can oc cur EUU65800 WARNING Battery electrolyte is poisonous and dan gerous causing severe burns etc It con tains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physi cian immediately EYES Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or
61. t of left side crankcase cover 8 11 2 Maximum level mark 1 Level window 3 Minimum level mark EUUO4000 MOTE s en Wait a few minutes until the oil level set tles before checking c The oil level should be between the maximum and minimum marks If the level is low fill the engine with suffi cient oil to the specified level 2 Engine oil and oil filter element re placement a Warm up the engine for a few min utes b Stop the engine Place an oil pan un der the engine and remove the oil filler cap 1 Drain plug d Remove the oil filter bolts oil filter and O ring c Remove the drain plug and drain the oil g 12 1 Oil filter cover 2 Oil filter bolt x 3 e Reinstall the drain plug and tighten it to the specified torque Tightening torque Drain plug 43 Nm 4 3 m kg 31 ft Ib f Install the new oil filter new O ring and the filter cover Then tighten the oil filter bolts to the specified torque 2 Oil filter 1 O ring 8 13 Tightening torque Oil filter bolts 10 Nm 1 0 m kg 7 2 ft lb EUU04101 NOTE Make sure the O ring is seated properly g Fill the engine with oil Install the oil filler cap and tighten it Recommended oil See page 6 5 Oil quantity Total amount 3 2 L 2 8 Imp at 3 4 US qt Periodic oil change 2 6 L 2 3 Imp qt 2 7 US qt With oil filter replacement 2 8 L 2 5 Imp qt 3 0 US qt
62. tem Do not operate the motorcycle until the fail ure in the brake system is corrected Ask a Yamaha dealer for immediate repairs A soft spongy feeling could indicate a haz ardous condition in the brake system 6 3 2 Brake fluid Check the brake fluid level Fill the master cylinder with brake fluid if nec essary See page 8 22 for details Recommended brake fluid DOT 4 EUU13100 NOTE S If DOT 4 is not available DOT 3 can be used Check the disc pads Refer to page 8 21 4 Check the brake shoes Refer to page 8 22 EUUO2201 NOTE When this brake service is necessary con sult a Yamaha dealer EAE11303 Front brake fluid leakage Apply the brake for a few minutes Check to see if any brake fluid leaks out from the pipe joints or the master cylinder EUUS37801 Brake fluid may deteriorate painted sur faces or plastic parts Never spill any fluid If spilled clean it up immediately EUUG2500 WARNING If brake fluid leakage is found ask a Yamaha dealer for immediate repairs Such leakage could indicate a hazardous condition EAE20002 Clutch Check the free play in the clutch lever and make sure the clutch operates properly If the free play is incorrect adjust it See page 8 24 for details EAE30104 Throttle grip Turn the throttle grip to see if it operates properly Make sure the grip returns by spring force when released There should be a free play of 3 5 mm
63. ughly familiar with your motorcycle and all of its controls Many motorcycle accidents have been caused by motorcycle operator errors A typ ical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars and both feet on the op erator footrests during operation to maintain control of the motorcycle b The passenger should always hold on to the operator or the seat strap or grab bar if the motorcycle is so equipped with both hands and keep both feet on the passenger footrests c Never carry a passenger unless he or she can firmly place both feet on the passen ger footrests Never ride under the influence of alcohol or drugs This motorcycle is designed for on road use only It is not suitable for off road use 1 3 PROTECTIVE APPAREL The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries 1 Always wear an approved helmet 2 Wear a face shield or goggles Wind on your unprotected eyes
64. using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 8 29 Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly The battery fluid should be checked at least once a month The level should be between the minimum level and maximum level marks Use only distilled water if refilling is necessary 2 Minimum level mark 1 Maximum level mark EUU33800 Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water Storage 1 When the motorcycle will not be used for a month or longer remove the bat tery and store it in a cool dark place Completely recharge the battery be fore reinstalling 2 If the battery will be stored for longer than two months check the specific gravity of the fluid at least once a month and recharge the battery when it is too low 3 Always make sure the connections are correct when putting the battery back in the motorcycle Make sure the breather pipe is properly connected and is not damaged or obstructed EAI90304 Fuse replacement 1 The fuse box is located under the seat 2 If any fuse is blown turn off the main switch and the switch of the circuit in question Install a new fuse of speci fied amperage Turn on the switches and see if the electrical device oper ates If the fuse immediately blows again consult a Yamaha deal
65. vidual using any part which is certified if applicable EUU63200 WARNING If you are not familiar with motorcycle ser vice this work should be done by a Yamaha dealer 8 1 EAHO00300 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPECIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CON TROLS NOT ONLY FUNCTION TO EN SURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOL LOWING TABLES OF PERIODIC MAINTE NANCE THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES EAH10200 Tool kit The service information included in this manual is intended to provide you the owner with the necessary information for completing some of your own preventive maintenance and minor repairs The tools provided in the owner s tool kit are to as sist you in the performance of periodic maintenance However some other tools such as a torque wrench are also neces sary to perform the maintenance correctly 1 Tool kit 8 2 EUU 18500 NOTE If you do not have necessary tools re quired during a service operation take your motorcycle to a Yamaha dealer for service EUU63301 A WARNING Modifications t
66. ype only NOTE For farther odometer reading beyond those listed repeat the above maintenance at the pe riod established 1 Every 6 000 km 3 800 mi and 2 Every 12 000 km 7 600 mi and 3 Every 24 000 km 15 200 mi intervals 8 4 General maintenance lubrication ITEM ROUTINE TYPE 600 mi or Warm up engine before draining E Replace shoes if necessary 1 month Clean with Brake system Rear ODOMETER READINGS HET 2 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or or or 7 months 13 months 19 months 25 months 31 months 1 000 km See page 6 5 air Replace if necessary Adjust free play Replace pads if necessary Front compressed Adjust free play Check oil level and leakage i Replace every SAE 80 API GL 4 Final gear oil 000 km hypoid gear oil 15 000 mi or 24 months 8 5 ROUTINE Apply chain lube thoroughly Check bearing assembly for looseness Moderately repack every 24 000 km 15 200 mi Control and meter cable Swingarm pivot bearing Brake Clutch lever pivot shaft Brake pedal and shift pedal shaft Apply chain lube lightly Lubricate Apply chain lube lightly e Check operation and lubricate Apply chain lube lightly Che

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