2000 YAMAHA XV535 service

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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1. Tool kit
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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.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
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NOTE:
lThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.
lHydraulic brake system
¥ When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly
and fill as required.
¥ Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
¥ Replace the brake hoses every four years or if cracked or damaged.
22 Engine oil filter element¥ Replace.ÖÖ
23 Final gear oil¥ Check oil level and vehicle for oil leakage.
¥ Change oil at initial 1,000 km and thereafter every 24,000 km
or 24 months (whichever comes first).ÖÖÖ 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)

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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.
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Tires
To ensure maximum performance,
long service, and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.
EW000082
Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed.
Maximum load*220 kg (except for CH, A)
218 kg (for CH, A)
Cold tire pressure Front Rear
Up to 90 kg200 kPa
(2.00 kg/cm
2,
2.00 bar)225 kPa
(2.25 kg/cm2,
2.25 bar)
90 kg load ~
Maximum load*200 kPa
(2.00 kg/cm
2,
2.00 bar)250 kPa
(2.50 kg/cm2,
2.50 bar)
* Load is the total weight of cargo, rider, passenger
and accessories.

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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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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
EW000112
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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1
1
1. Screw (´ 2)
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Turn signal and taillight bulb
replacement
1. Remove the screws and the lense.
1
1. Bulb (´ 2)
2. Push the bulb inward and turn it
counterclockwise.
3. Place a new bulb in the socket.
Push the bulb inward and turn it
clockwise until it engages into the
socket.
4. Install the lense and the screws.
EC000108
CAUTION:
Do not over-tighten the screws as
the lense may break.
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Troubleshooting
Although Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting 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 motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.

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SPECIFICATIONS
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Specifications
Model XV535
Dimensions
Overall length 2,225 mm
(except for CH, S, SF, N)
2,250 mm (for CH, S, SF, N)
Overall width 780 mm
Overall height 1,120 mm
Seat hight 720 mm
Wheelbase 1,520 mm
Ground clearance 160 mm
Minimum turning radius 2,900 mm
Basic weight (with oil and full
fuel tank)
195 kg (except for CH, A)
197 kg (for CH, A)
Engine
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement V type 2-cylinder
Displacement 535 cm
3
Bore´ Stroke 76.0 ´ 59.0 mm
Compression ratio 9:1
Starting system Electric starter
Lubrication system Wet sump
Engine oil
Ty p e
Recommended engine oil
classiÞcation API Service SE, SF, SG type or
higher
Quantity
Periodic oil change 2.6 L
With oil Þlter replacement 2.8 L
Total amount 3.2 L
-20û -10û 0û
10û20û 30û
40û50ûC
SAE 10W/30
SAE 15W/40
SAE 20W/40
SAE 20W/50
SAE 10W/40
CAUTION:
Be sure to use motor oils that do not contain anti-fric-
tion modifiers. Passenger car motor oils (often labeled
ÒEnergy ConservingÓ) contain anti-friction additives
which will cause clutch and/or starter clutch slippage,
resulting in reduced component life and poor engine
performance.
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