2000 YAMAHA XV535 tires

L
4-1
PRE-OPERATION CHECKS
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Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake¥ Check operation, free play, fluid level and vehicle for fluid leakage.
¥ Fill with DOT 4 (or DOT 3) brake fluid if necessary.
6-17 ~ 6-21
Rear brake¥ Check operation, condition and free play.
¥ Adjust if necessary.
Clutch¥ Check operation, condition and free play.
¥ Adjust if necessary.6-17
Throttle grip and housing¥ Check for smooth operation.
¥ Lubricate if necessary.6-13
Engine oil¥ Check oil level.
¥ Fill with oil if necessary.6-7 ~ 6-9
Final gear oil¥ Check vehicle for leakage. 6-9 ~ 6-10
Wheels and tires¥ Check tire pressure, wear, damage and spoke tightness.
¥ Tighten spokes if necessary.6-14 ~ 6-16
Control and meter cables¥ Check for smooth operation.
¥ Lubricate if necessary.6-21
Brake and shift pedal
shafts¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
Brake and clutch lever
pivots¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
EAU01114

R
PERIODIC MAINTENANCE AND MINOR REPAIR
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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
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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)

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6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00637
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.
EAU00647
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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6-15
PERIODIC MAINTENANCE AND MINOR REPAIR
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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

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6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
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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.

L
7-3
MOTORCYCLE CARE AND STORAGE
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1. Clean your motorcycle with cold
water and soap after the engine
has cooled down.
ECA00012
CAUTION:
Do not use warm water since it in-
creases the corrosive action of the
salt.
2. Be sure to apply a corrosion pro-
tection spray on all (even chrome-
and nickel-plated) metal surfaces
to prevent corrosion.After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainless-
steel parts, including the exhaust
system. (Even the thermally in-
duced discoloring of stainless-
steel exhaust systems can be re-
moved through polishing.)
3. To prevent corrosion, it is recom-
mended to apply a corrosion pro-
tection spray on all (even chrome-
and nickel-plated) metal surfaces.
4. Use spray oil as a universal clean-
er to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing it or covering it.
EWA00001
Make sure that there is no oil or wax
on the brakes and tires. If neces-
sary, clean the brake discs and lin-
ings with a regular brake disc
cleaner or acetone, and wash the
tires with warm water and mild soap.
Then, carefully test the motorcycle
for its braking performance and cor-
nering behavior.

L
7-5
MOTORCYCLE CARE AND STORAGE
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a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs and place the
spark plugs on the cylinder head
so that the electrodes are
grounded. (This will limit sparking
during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, install the spark
plugs and then the spark plug
caps.
EWA00003
When turning the engine over, be
sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking.6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, then raise the
motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover up the muffler outlets with
plastic bags to prevent moisture
from entering.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery in
an excessively cold or warm place
(less than 0ûC or more than 30ûC).
For more information, see ÒBattery
storageÓ in the chapter ÒPERIODIC
MAINTENANCE AND MINOR
REPAIRSÓ.
NOTE:
Make any necessary repairs before
storing the motorcycle.