Page 12 of 87
R
2-2
DESCRIPTION
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-2.frame
Right view
10. Rear turn signal light (page 6-29)
11. Sub fuel tank
12. Fuel tank (page 3-5)13. Front turn signal light (page 6-29)
14. Rear brake pedal (page 3-4)
15. Battery (page 6-25)
Page 15 of 87

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3-1
INSTRUMENT AND CONTROL FUNCTIONS
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame
EAU00027
EAU00028
Main switch
The main switch controls the ignition
and lighting systems. Its operation is
described below.
EAU00036
ON
Electrical circuits are switched on. The
engine can be started. The key cannot
be removed in this position.
EAU00038
OFF
All electrical circuits are switched off.
The key can be removed in this posi-
tion.
1. Push
2. Release
3. Turn
EAU00055
P (Parking)
The taillight and auxiliary light come on
but all other circuits are off. With the
key at ÒOFFÓ, push it into the main
switch and release it. Then turn it coun-
terclockwise to ÒPÓ, and remove it. (Do
not use this position for an extended
length of time as the battery may dis-
charge.) To cancel the parking, turn the
key clockwise.
1. High beam indicator light Ò Ó
2. Neutral indicator light Ò Ó
3. Turn indicator light Ò Ó
EAU00056
Indicator lights
EAU00063
High beam indicator light Ò Ó
This indicator comes on when the
headlight high beam is used.
EAU00061
Neutral indicator light Ò Ó
This indicator comes on when the
transmission is in neutral.
EAU00057
Turn indicator light Ò Ó
This indicator flashes when the turn
switch is moved to the left or right.
Page 28 of 87
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4-2
PRE-OPERATION CHECKS
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-4.frame
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be thoroughly accom-
plished in a very short time; and the added safety it assures is more than worth the time involved.
If any item in the PRE-OPERATION CHECK is not working properly, have it inspected and repaired before operating
the motorcycle.
Sidestand pivot¥ Check for smooth operation.
¥ Lubricate if necessary.6-23
Chassis fasteners¥ Make sure that all nuts, bolts and screws are properly tightened.
¥ Tighten if necessary.Ñ
Fuel tank¥ Check fuel level.
¥ Fill with fuel if necessary.3-5 ~ 3-6
Lights, signals and
switches¥ Check for proper operation. 6-27 ~ 6-29
Battery¥ Check fluid level.
¥ Fill with distilled water if necessary.6-25 ~ 6-26 ITEM CHECKS PAGE
Page 38 of 87

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PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6TOC.frame
Tool kit ................................................................ 6-1
Periodic maintenance and lubrication................. 6-2
Spark plugs ........................................................ 6-5
Engine oil............................................................ 6-7
Final gear oil ....................................................... 6-9
Air filter ............................................................. 6-10
Carburetor adjustment ...................................... 6-12
Idle speed adjustment ...................................... 6-13
Throttle cable free play inspection .................... 6-13
Valve clearance adjustment ............................. 6-14
Tires ................................................................. 6-14
Wheels ............................................................. 6-16
Clutch lever free play adjustment ..................... 6-17
Front brake lever free play adjustment ............. 6-17
Rear brake pedal height and free play
adjustment ...................................................... 6-18
Brake light switch adjustment ........................... 6-19
Checking the front brake pads and
rear brake shoes ............................................ 6-19Inspecting the brake fluid level.......................... 6-20
Brake fluid replacement .................................... 6-21
Cable inspection and lubrication ....................... 6-21
Throttle cable and grip lubrication ..................... 6-22
Brake and shift pedal lubrication ....................... 6-22
Brake and clutch lever lubrication ..................... 6-22
Sidestand lubrication......................................... 6-23
Rear suspension lubrication.............................. 6-23
Front fork inspection ......................................... 6-23
Steering inspection ........................................... 6-24
Wheel bearings ................................................. 6-24
Battery............................................................... 6-25
Fuse replacement ............................................. 6-27
Headlight bulb replacement .............................. 6-27
Turn signal and taillight bulb replacement ........ 6-29
Troubleshooting ................................................ 6-29
Troubleshooting chart ....................................... 6-30
Page 40 of 87

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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)
1
*Fuel line¥ Check fuel hoses and vacuum hose for cracks or damage.
¥ Replace if necessary.ÖÖ
2 Spark plugs¥ Check condition.
¥ Clean, regap or replace if necessary.ÖÖÖ
3
*Fuel filter¥ Check condition.
¥ Replace if necessary.Ö
4
*Valves¥ Check valve clearance.
¥ Adjust if necessary.ÖÖÖ
5 Air filter¥ Clean or replace if necessary.ÖÖ
6
*Battery¥ Check electrolyte level and specific gravity.
¥ Correct or recharge if necessary.
¥ Make sure that the breather hose is properly routed.ÖÖ
7Clutch¥ Check operation.
¥ Adjust or replace cable.ÖÖÖ
8
*Front brake¥ Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
¥ Correct accordingly.
¥ Replace brake pads if necessary.ÖÖÖ
9
*Rear brake¥ Check operation.
¥ Adjust brake pedal free play and replace brake shoes if necessary.ÖÖÖ
10
*Wheels¥ Check balance, runout, spoke tightness and for damage.
¥ Tighten spokes and rebalance, replace if necessary.ÖÖ
Page 63 of 87

L
6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
1. Battery
2. Pass through the battery case
3. Pass through the frame
4. Pass through the cable guide
5. Pass through the engine bracket
6. Battery breather hose
EAU00798
Battery
Check the level of the battery electro-
lyte and make sure that the terminals
are tight. Fill with distilled water if the
electrolyte level is low. If the motor-
cycle is equipped with optional electri-
cal accessories, the battery tends to
discharge more quickly, so be sure to
recharge it periodically.
EC000099
CAUTION:
When inspecting the battery, be
sure the breather hose is routed cor-
rectly. If the breather hose is posi-
tioned 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
occur.
EW000116
Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
ANTIDOTE:
lEXTERNAL: Flush with water.
lINTERNAL: Drink large quanti-
ties of water or milk. Follow with
milk of magnesia, beaten egg,
or vegetable oil. Call a physi-
cian immediately.
lEYES: 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
using in an enclosed space. Always
shield your eyes when working near
batteries. KEEP OUT OF REACH OF
CHILDREN.
Page 64 of 87

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6-26
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
1. Maximum level mark
2. Minimum level mark
Replenishing the battery fluid
A poorly maintained battery will cor-
rode and discharge quickly. The bat-
tery fluid should be checked at least
once a month. The level should be be-
tween the minimum level and maxi-
mum level marks. Use only distilled
water if refilling is necessary.
EC000100
CAUTION:
Normal tap water contains minerals
which are harmful to a battery;
therefore, refill only with distilled
water.Battery storage
lWhen the motorcycle will not be
used for a month or longer, re-
move the battery, fully charge it
and store it in a cool, dry place.
Completely recharge the battery
before reinstalling.
lIf 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.
lAlways make sure the connec-
tions are correct when putting the
battery back in the motorcycle.
Make sure the breather hose is
properly connected and is not
damaged or obstructed.
Page 68 of 87
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6-30
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EAU01562
Troubleshooting chart
EW000125
Never check the fuel system while smoking or in the vicinity of an open flame.
Check if there is fuel
in the fuel tank.
1. FuelEnough fuel.
No fuel.Go to compression check.
Supply fuel.
Use electric starter.
2. CompressionThere is compression.
No compression.Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark
plugs and
check electrode.
3. IgnitionWet.
Dry.Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesnÕt start, go to battery
check.
Open throttle half-way and start
the engine.
Use the electric starter.
4. BatteryEngine turns over
quickly.
Engine turns over
slowly.Battery good.
Check fluid, recharge,
check connections.
Engine doesnÕt start, ask a Yamaha
dealer to inspect.
Engine doesnÕt start, go to compression check.