2000 YAMAHA XV535 steering

R
INSTRUMENT AND CONTROL FUNCTIONS
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3TOC.frame
Main switch ........................................................................................ 3-1
Indicator lights .................................................................................... 3-1
Speedometer...................................................................................... 3-2
Handlebar switches ............................................................................ 3-2
Clutch lever ........................................................................................ 3-3
Shift pedal .......................................................................................... 3-4
Front brake lever ................................................................................ 3-4
Rear brake pedal................................................................................ 3-4
Fuel tank cap...................................................................................... 3-5
Fuel .................................................................................................... 3-5
Starter (choke) Ò Ó........................................................................... 3-6
Steering lock ...................................................................................... 3-6
Seats .................................................................................................. 3-7
Helmet holder ..................................................................................... 3-8
Rear shock absorber adjustment ....................................................... 3-9
Sidestand ........................................................................................... 3-9
Sidestand/clutch switch operation check ......................................... 3-10

R
3-6
INSTRUMENT AND CONTROL FUNCTIONS
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-3.frame
EAU00185
CAUTION:
Always wipe off spilled fuel immedi-
ately with a dry and clean soft cloth.
Fuel may deteriorate painted surfac-
es or plastic parts.
EAU00191
NOTE:
If knocking or pinging occurs, use a dif-
ferent brand of gasoline or higher oc-
tane grade.Recommended fuel:
Regular unleaded gasoline with
a research octane number of 91
or higher.
Fuel tank capacity:
Total:
13.5 L
Reserve:
2.5 L
1. Starter (choke) Ò Ó
EAU02976
Starter (choke) Ò Ó
Starting a cold engine requires a richer
air-fuel mixture. A separate starter cir-
cuit supplies this mixture.
Move in direction a
to turn on the
starter (choke).
Move in direction b
to turn off the
starter (choke).
1. Steering lock
EAU02934
Steering lock
To lock the steering
Turn the handlebars all the way to the
right and open the steering lock cover.
Insert the key and turn it 1/8 turn coun-
terclockwise. Then, push the key in
while turning the handlebars slightly to
the left and turn the key 1/8 turn clock-
wise.
Check that the steering is locked, re-
move the key and close the lock cover.
To unlock the steering
Insert the key, push it in and turn it 1/8
turn counterclockwise so that it moves
out. Then, release and remove the key.

R
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

L
6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
11*Tires¥ Check tread depth and for damage.
¥ Replace if necessary.
¥ Check air pressure.
¥ Correct if necessary.ÖÖ
12
*Wheel bearings¥ Check bearing for looseness or damage.
¥ Replace if necessary. ÖÖ
13
*Swingarm¥ Check swingarm pivoting point for play.
¥ Correct if necessary.
¥ Lubricate with molybdenum disulfide grease.ÖÖ
14
*Steering bearings¥ Check bearing play and steering for roughness.
¥ Correct accordingly.
¥ Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
15
*Chassis fasteners¥ Make sure that all nuts, bolts and screws are properly tightened.
¥ Tighten if necessary.ÖÖ
16 Sidestand¥ Check operation.
¥ Lubricate and repair if necessary.ÖÖ
17
*Sidestand switch¥ Check operation.
¥ Replace if necessary.ÖÖÖ
18
*Front fork¥ Check operation and for oil leakage.
¥ Correct accordingly.ÖÖ
19
*Rear shock absorber
assemblies¥ Check operation and shock absorbers for oil leakage.
¥ Replace shock absorber assembly if necessary.ÖÖ
20
*Carburetors¥ Check engine idling speed, synchronization and starter operation.
¥ Adjust if necessary.ÖÖÖ
21 Engine oil¥ Check oil level and vehicle for oil leakage.
¥ Correct if necessary.
¥ Change. (Warm engine before draining.)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)

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.

L
9-1
CONSUMER INFORMATION
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-9.frame
EAU02944
Identification number records
Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION
NUMBER:
2. VEHICLE IDENTIFICATION
NUMBER:
3. MODEL LABEL INFORMATION:
EAU01039
1. Key identification number
EAU01042
Key identification number
The key identification number is
stamped on the key. Record this num-
ber in the space provided and use it for
reference when obtaining a new key.
1. Vehicle identification number
EAU01043
Vehicle identification number
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space pro-
vided.
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motor-
cycle with the licensing authority in
your state.

R
INDEX
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/XV535IX.-
S
Seats ..................................................... 3-7
Shift pedal .............................................. 3-4
Shifting ................................................... 5-4
Sidestand ............................................... 3-9
Sidestand lubrication ........................... 6-23
Sidestand/clutch switch operation
check ................................................. 3-10
Spark plugs ............................................ 6-5
Specifications ........................................ 8-1
Speedometer ......................................... 3-2
Start switch ............................................ 3-3
Starter (choke) Ò Ó .............................. 3-6
Starting a warm engine .......................... 5-3
Starting the engine ................................ 5-1
Steering inspection .............................. 6-24
Steering lock .......................................... 3-6
Storage .................................................. 7-4
T
Throttle cable and grip lubrication ....... 6-22
Throttle cable free play inspection ....... 6-13
Tips for reducing fuel consumption ........ 5-5
Tires ..................................................... 6-14
Tool kit ................................................... 6-1
Troubleshooting ................................... 6-29
Troubleshooting chart .......................... 6-30
Turn indicator light ................................. 3-1
Turn signal and taillight bulb
replacement ...................................... 6-29
Turn signal switch .................................. 3-2
V
Valve clearance adjustment ................. 6-14
Vehicle identification number ................. 9-1
W
Wheel bearings .................................... 6-24
Wheels ................................................. 6-16