2000 YAMAHA XV535 brake

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PERIODIC MAINTENANCE AND MINOR REPAIR
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lOperating the motorcycle with
excessively worn tires decrease
riding stability and can lead to
loss of control. Have excessive-
ly worn tires replaced by a
Yamaha dealer immediately.
Brakes, tires, and related wheel
parts replacement should be
left to a Yamaha Service Techni-
cian.
lPatching a punctured tube is
not recommended. If it is abso-
lutely necessary to do so, use
great care and replace the tube
as soon as possible with a good
quality replacement.
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Wheels
To ensure maximum performance,
long service, and safe operation, note
the following:
lAlways inspect the wheels before
a ride. Check for cracks, bends or
warpage of the wheel. Be sure the
spokes are tight and undamaged.
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 de-
formed or cracked, it must be re-
placed.
lTires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse han-
dling characteristics, and short-
ened tire life.
lRide at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.

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

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lCheck the brake lever free play.
Be sure the brake is working
properly.
lA soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake sys-
tem. This air must be removed
by bleeding the brake system
before the motorcycle is operat-
ed. Air in the system will cause
greatly diminished braking ca-
pability and can result in loss of
control and an accident. Have a
Yamaha dealer inspect and
bleed the system if necessary.
1. Footrest
2. Pedal height
a. Free play
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Rear brake pedal height and
free play adjustment
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It is advisable to have a Yamaha
dealer make this adjustment.
The brake pedal height should be ad-
justed before adjusting the brake pedal
free play.
Pedal height
The brake pedal should be positioned
approximately 38 mm above the top of
the footrest.
1. Adjusting bolt
2. Locknut
1. Loosen the locknut.
2. Turn the adjusting bolt in direction
a
to raise pedal height or in direc-
tionb
to lower pedal height.
3. Tighten the locknut.
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After adjusting the pedal height ad-
just brake pedal free play.

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

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1. Wear limit
2. Wear indicator
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Rear brake
Apply the brake and inspect the wear
indicator.
If the indicator reaches the wear limit
line, ask a Yamaha dealer to replace
the shoes.
1. Minimum level mark
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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:
lWhen checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.
lUse only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.
NOTE:
If DOT 4 is not available, DOT 3 can be
used.
lRefill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
lBe careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock. Recommended brake fluid: DOT 4

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lBrake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
lHave a Yamaha dealer check the
cause if the brake fluid level goes
down.
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Brake fluid replacement
The brake fluid should be replaced only
by trained Yamaha service personnel.
Have the Yamaha dealer replace the
following components during periodic
maintenance or when they are dam-
aged or leaking:
loil seals (every two years)
lbrake hoses (every four years)
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Cable inspection and
lubrication
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Damage to the outer housing of ca-
bles may lead to internal rusting and
interfere with the cable movement.
Replace damaged cables as soon as
possible to prevent unsafe condi-
tions.
Lubricate the cables and cable ends. If
a cable does not operate smoothly, ask
a Yamaha dealer to replace it.
Recommended lubricant:
Engine oil

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Throttle cable and grip
lubrication
The throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the
metal surface of the grip assembly with
a suitable all-purpose grease.
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Brake and shift pedal
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil
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Brake and clutch lever
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil

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Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front brake.
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
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CAUTION:
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
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Steering inspection
Periodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. Place a
stand under 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 steer-
ing. Inspection is easier if the front
wheel is removed.
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Securely support the motorcycle so
there is no danger of it falling over.
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Wheel bearings
If there is play in the front or rear wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer in-
spect the wheel bearings.