2000 YAMAHA XV535 air condition

L
6-1
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EAU00464
Periodic inspection, adjustment and lu-
brication will keep your motorcycle in
the safest and most efficient condition
possible. Safety is an obligation of the
motorcycle owner. The maintenance
and lubrication schedule chart should
be considered strictly as a guide to
general maintenance and lubrication
intervals. YOU MUST TAKE INTO
CONSIDERATION THAT WEATHER,
TERRAIN, GEOGRAPHICAL LOCA-
TIONS, AND A VARIETY OF INDIVID-
UAL USES ALL TEND TO DEMAND
THAT EACH OWNER ALTER THIS
TIME SCHEDULE TO SHORTER IN-
TERVALS TO MATCH THE ENVI-
RONMENT. The most important points
of motorcycle inspection, adjustment,
and lubrication are explained in the fol-
lowing pages.
EW000060
If you are not familiar with motor-
cycle service, this work should be
done by a Yamaha dealer.
EAU00462
1. Tool kit
EAU00469
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 pre-
ventive maintenance and minor re-
pairs. The tools provided in the ownerÕs
tool kit are to assist you in the perfor-
mance of periodic maintenance. How-
ever, some other tools such as a torque
wrench are also necessary to perform
the maintenance correctly.
NOTE:
If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer
for service.
EW000063
Modifications to this motorcycle not
approved by Yamaha may cause
loss of performance, and render it
unsafe for use. Consult a Yamaha
dealer before attempting any chang-
es.

R
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

L
6-5
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
2 1
1. Cylinder head cover
2. Screw (´ 2)
EAU01486
Spark plugs
Removal
1. Remove the rear right and front
left cylinder head covers by re-
moving the screws.
2. Remove the spark plug caps.
1
1. Spark plug wrench
3. Use the spark plug wrench in the
tool kit to remove the spark plugs
as shown.
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
medium-to-light tan color for a motor-
cycle that is being ridden normally. If
one spark plug shows a distinctly differ-ent color, there could be something
wrong with the engine. Do not attempt
to diagnose such problems yourself. In-
stead, take the motorcycle to a
Yamaha dealer. You should periodical-
ly remove and inspect the spark plugs
because heat and deposits will cause
any spark plug to slowly break down
and erode. If electrode erosion be-
comes excessive, or if carbon and oth-
er deposits are excessive, you should
replace the spark plug with the speci-
fied plug.
Specified spark plug:
For CH:
BPR7ES (NGK) or
W22EPR-U (DENSO)
Except for CH:
BPR6ES (NGK) or
W20EPR-U (DENSO)

R
6-10
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
NOTE:
ÒGL-4Ó is a quality and additive rating.
Hypoid gear oils rated ÒGL-5Ó or ÒGL-6Ó
may also be used.
5. Install and tighten the filler bolt to
the specified torque.
6. After replacing the final gear oil, be
sure to check for oil leakage. Final gear case capacity:
0.19 L
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid
gear oil may be used for all
conditions.
Tightening torque:
Oil filler bolt:
23 Nm (2.3 mákg)
1. Fuel tank
2. Bolt (´ 3)
EAU02998
Air filter
The air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seats. (See page 3-7
for seat removal and installation
procedures.)
2. Remove the fuel tank bolts.
1. Screw
3. Lift the front of the fuel tank up-
ward and position it away from the
air filter. (Do not remove the fuel
tank.)
EW000071
lSupport the fuel tank carefully
during this procedure.
lDo not tilt the fuel tank too
much or pull it too hard be-
cause the fuel hose connec-
tions may become loose
causing fuel leakage.
4. Remove the air filter case cover
screw.

L
6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EW000083
Proper loading of your motorcycle
is important for several characteris-
tics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and dis-
tribute the weight evenly from side
to side. Properly adjust the suspen-
sion for your load, and 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 maximum load of the
motorcycle. Operation of an over-
loaded motorcycle could cause tire
damage, an accident, or even injury.
a. Tread depth
1. Side wall
Tire inspection
Always check the tires before operating
the motorcycle. If center tread depth
reaches the limit as shown, 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 replaced.
NOTE:
These limits may be different by regula-
tion from country to country. If so, con-
form to the limits specified by the
regulations of your own country.
FRONT
Manufacturer Size Type
Bridgestone 3.00-19 49S L303A
Dunlop 3.00-19 49S F14G
REAR
Manufacturer Size Type
Bridgestone 140/90-15 M/C 70S G508
Dunlop 140/90-15 M/C 70S K425
Minimum tire tread depth
(front and rear)1.6 mm

R
6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EAU00681
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.
EAU00685
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.

R
6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
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.
EC000098
CAUTION:
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU00794
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.
EW000115
Securely support the motorcycle so
there is no danger of it falling over.
EAU01144
Wheel bearings
If there is play in the front or rear wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer in-
spect the wheel bearings.