2001 YAMAHA XV535 engine

OPERATION AND IMPORTANT RIDING POINTS
5
Starting a cold engine ....................................................................... 5-1
Starting a warm engine ...................................................................... 5-2
Shifting .............................................................................................. 5-3
Recommended shift points (for Switzerland only) .............................. 5-3
Tips for reducing fuel consumption .................................................... 5-4
Engine break-in ................................................................................. 5-4
Parking ............................................................................................... 5-5
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5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@ l
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
l
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
l
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU02997*
Starting a cold engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:l
The transmission is in the neutral
position.
l
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
@ l
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-11.
l
Never ride with the sidestand
down.
@
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
2. Shift the transmission into the neu-
tral position.NOTE:@ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit. @3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6 for starter (choke) opera-
tion.)
4. Start the engine by pushing the
start switch.NOTE:@ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. @
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM

OPERATION AND IMPORTANT RIDING POINTS
5-2
5 5. After starting the engine, move the
starter (choke) lever back halfway.
ECA00045
CAUTION:@ For maximum engine life, never ac-
celerate hard when the engine is
cold! @6. When the engine is warm, turn the
starter (choke) off.NOTE:@ The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. @
EAU01258
Starting a warm engineFollow the same procedure as for start-
ing a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM

OPERATION AND IMPORTANT RIDING POINTS
5-3
5
EAU00423
Shifting Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the
illustration.NOTE:@ To shift the transmission into the neu-
tral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it. @
EC000048
CAUTION:@ l
Even with the transmission in
the neutral position, do not
coast for long periods of time
with the engine off, and do not
tow the motorcycle for long dis-
tances. The transmission is
properly lubricated only when
the engine is running. Inade-
quate lubrication may damage
the transmission.
l
Always use the clutch while
changing gears to avoid dam-
aging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
@
EAU02941
Recommended shift points
(for Switzerland only)The recommended shift points during
acceleration are shown in the table
below.CF-01ENOTE:@ When shifting down two gears at a
time, reduce the speed accordingly
(e.g., down to 35 km/h when shifting
from 4th to 2nd gear). @
1. Shift pedal
N. Neutral position
Shift point
(km/h)
1st®2nd
2nd®3rd
3rd®4th
4th®5th23
36
50
60
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OPERATION AND IMPORTANT RIDING POINTS
5-4
5
EAU00424
Tips for reducing fuel
consumptionFuel consumption depends largely on
your riding style. Consider the following
tips to reduce fuel consumption:l
Thoroughly warm up the engine.
l
Turn the starter (choke) off as
soon as possible.
l
Shift up swiftly, and avoid high en-
gine speeds during acceleration.
l
Do not rev the engine while shift-
ing down, and avoid high engine
speeds with no load on the engine.
l
Turn the engine off instead of let-
ting it idle for an extended length
of time (e.g., in traffic jams, at traf-
fic lights or at railroad crossings).
EAU00436
Engine break-in There is never a more important period
in the life of your engine than the period
between 0 and 1,000 km. For this rea-
son, you should read the following ma-
terial carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,000 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full-throttle oper-
ation or any condition that might result
in engine overheating must be avoided.
EAU00444*
0–150 kml
Avoid prolonged operation above
1/3 throttle.
l
After every hour of operation, stop
the engine, and then let it cool for
five to ten minutes.
l
Vary the engine speed from time
to time. Do not operate the engine
at one set throttle position.
150–500 km
l
Avoid prolonged operation above
1/2 throttle.
l
Rev the engine freely through the
gears, but do not use full throttle at
any time.
500–1,000 km
Avoid prolonged operation above
3/4 throttle.
EC000056*
CAUTION:@ After 1,000 km of operation, the en-
gine oil and final gear oil must be
changed, and the oil filter element
replaced. @
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OPERATION AND IMPORTANT RIDING POINTS
5-5
51,000 km and beyond
Avoid prolonged full-throttle operation.
Vary the speed occasionally.
EC000049
CAUTION:@ If any engine trouble should occur
during the engine break-in period,
immediately have a Yamaha dealer
check the vehicle. @
EAU00460
ParkingWhen parking, stop the engine, and
then remove the key from the main
switch.
EW000058
WARNING
@ l
Since the engine and exhaust
system can become very hot,
park in a place where pedestri-
ans or children are not likely to
touch them.
l
Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
@
E_3bt.book Page 5 Thursday, September 7, 2000 10:01 AM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Checking the spark plugs .................................... 6-5
Engine oil and oil filter element ............................ 6-7
Final gear oil ........................................................ 6-9
Cleaning the air filter element ............................ 6-11
Adjusting the carburetors .................................... 6-13
Adjusting the engine idling speed ....................... 6-13
Adjusting the throttle cable free play ................... 6-14
Adjusting the valve clearance ............................. 6-14
Tires ................................................................... 6-15
Spoke wheels ..................................................... 6-17
Adjusting the clutch lever free play .................... 6-18
Adjusting the brake lever free play ...................... 6-19
Adjusting the brake pedal position and
free play ........................................................... 6-19
Adjusting the rear brake light switch ................... 6-21
Checking the front brake pads and rear
brake shoes ..................................................... 6-21
Checking the brake fluid level ............................ 6-22
Changing the brake fluid ..................................... 6-23Checking and lubricating the cables .................. 6-23
Checking and lubricating the throttle
grip and cable .................................................. 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-25
Checking and lubricating the brake and
clutch levers ..................................................... 6-25
Checking and lubricating the sidestand ............. 6-25
Lubricating the rear suspension ........................ 6-26
Checking the front fork ....................................... 6-27
Checking the steering ........................................ 6-27
Checking the wheel bearings ............................. 6-28
Battery ............................................................... 6-29
Replacing the fuses .......................................... 6-31
Replacing the headlight bulb .............................. 6-31
Replacing a turn signal light bulb or the
tail/brake light bulb ........................................... 6-33
Supporting the motorcycle ................................ 6-33
Front wheel ....................................................... 6-34
Rear wheel ........................................................ 6-35
Troubleshooting .................................................. 6-37
Troubleshooting chart ........................................ 6-38
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-3
6
10
*Brake hose• Check for cracks or damage.ÖÖÖÖ Ö
• Replace. (See NOTE on page 6-4.) Every 4 years
11*Wheels• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.ÖÖÖÖ
12*Tires• Check tread depth and for damage.
• Replace if necessary.
• Check air pressure.
• Correct if necessary.ÖÖÖÖ
13*Wheel bearings• Check bearing for looseness or damage.ÖÖÖÖ
14*Swingarm• Check operation and for excessive play.ÖÖÖÖ
• Lubricate with molybdenum disulfide grease. Every 50,000 km
15*Steering bearings• Check bearing play and steering for roughness.ÖÖÖÖÖ
• Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.ÖÖÖÖ Ö
17 Sidestand• Check operation.
• Lubricate.ÖÖÖÖ Ö
18*Sidestand switch• Check operation.ÖÖÖÖÖ Ö
19*Front fork• Check operation and for oil leakage.ÖÖÖÖ
20*Rear shock absorber
assemblies• Check operation and shock absorbers for oil leakage.ÖÖÖÖ
21*Carburetors• Check starter (choke) operation.
• Adjust engine idling speed and synchronization.ÖÖÖÖÖ Ö
22 Engine oil• Change.ÖÖÖÖÖ Ö
23 Engine oil filter element•Replace.ÖÖÖ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM