2001 YAMAHA XV535 warning

PERIODIC MAINTENANCE AND MINOR REPAIR
6-20
6 Brake pedal position
The brake pedal should be positioned
approximately 38 mm above the top of
the footrest as shown. Periodically
check the brake pedal position and, if
necessary, adjust it as follows.1. Loosen the locknut at the brake
pedal.
2. To raise the brake pedal, turn the
adjusting bolt in direction
a. To
lower the brake pedal, turn the ad-
justing bolt in direction
b.
3. Tighten the locknut.
EW000105
WARNING
@ After adjusting the brake pedal
height, the brake pedal free play
must be adjusted. @
Brake pedal free play
The brake pedal free play should mea-
sure 20–30 mm at the brake pedal end.
Periodically check the brake pedal free
play and, if necessary, adjust it as
follows.
To increase the brake pedal free play,
turn the adjusting nut at the brake rod
in direction
a. To decrease the brake
pedal free play, turn the adjusting nut in
direction
b.
1. Footrest
2. Distance between brake pedal and footrest
a. Brake pedal free play
1. Brake pedal position adjusting bolt
2. Locknut
1. Brake pedal free play adjusting nut
E_3bt.book Page 20 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03238
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever it
is damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
EAU02962
Checking and lubricating the
cablesThe operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
Recommended lubricant:
Engine oil
E_3bt.book Page 23 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU03165
Checking and lubricating the
sidestandThe operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
@ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. @
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
E_3bt.book Page 25 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-27
6
EAU02939
Checking the front forkThe condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic main-
tenance and lubrication chart.
To check the condition
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @Check the inner tubes for scratches,
damage and excessive oil leakage.To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handle-
bars several times to check if the
front fork compresses and re-
bounds smoothly.
EC000098
CAUTION:@ If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or re-
pair it. @
EAU00794
Checking the steeringWorn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as fol-
lows at the intervals specified in the pe-
riodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
@ Securely support the motorcycle so
that there is no danger of it falling
over. @
E_3bt.book Page 27 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-29
6
EAU00798
Battery A poorly maintained battery will cor-
rode and discharge quickly. The elec-
trolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.To check the electrolyte level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:@ Make sure that the motorcycle is posi-
tioned straight up when checking the
electrolyte level. @2. Check the electrolyte level in the
battery.NOTE:@ The electrolyte should be between the
minimum and maximum level marks. @
3. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.
EW000116
WARNING
@ l
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
l
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
1. Battery
2. Pass through the battery case.
3. Pass through the frame.
4. Pass through the guide.
5. Pass through the engine bracket.
6. Battery breather hose
1. Maximum level mark
2. Minimum level mark
E_3bt.book Page 29 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-32
6 2. Disconnect the headlight coupler,
and then remove the headlight unit
and bulb cover.3. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.
EW000119
WARNING
@ Headlight bulbs get very hot. There-
fore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down. @4. Place a new bulb into position, and
then secure it with the bulb holder.
EC000105
CAUTION:@ Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely af-
fected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner. @5. Install the bulb cover, and then
connect the coupler.
6. Install the headlight unit by install-
ing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
1. Headlight coupler
2. Headlight bulb cover
1. Headlight bulb holder
1. Do not touch this area.
E_3bt.book Page 32 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-34
6 To service the rear wheel
Raise the rear wheel off the ground by
using a motorcycle stand or, if a motor-
cycle stand is not available, by placing
a jack either under each side of the
frame in front of the rear wheel or under
each side of the swingarm.
EAU03239
Front wheel To remove the front wheel
EW000122
WARNING
_ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Disconnect the speedometer ca-
ble from the front wheel.2. Loosen the front wheel axle pinch
bolt, then the wheel axle.
3. Lift the front wheel off the ground
according to the procedure on
page 6-33.
4. Pull the wheel axle out, and then
remove the wheel.
ECA00048
CAUTION:_ Do not apply the brake after the
wheel has been removed together
with the brake disc, otherwise the
brake pads will be forced shut. _
1. Speedometer cable
1. Front wheel axle pinch bolt
2. Wheel axle
E_3bt.book Page 34 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU01394
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:_ Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg. _3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.5. Push down hard on the handlebar
several times to check for proper
fork operation.
6. Tighten the wheel axle to the
specified torque.
7. Install the front wheel axle pinch
bolt, and then tighten it to the
specified torque.
8. Connect the speedometer cable.
EAU01337
Rear wheel To remove the rear wheel
EW000122
WARNING
_ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Remove the axle nut cotter pin,
and then loosen the axle nut.
1. Retainer
Tightening torque:
Wheel axle:
58 Nm (5.8 m·kg)
Tightening torque:
Front wheel axle pinch bolt:
23 Nm (2.3 m·kg)
1. Axle nut cotter pin
2. Axle nut
E_3bt.book Page 35 Thursday, September 7, 2000 10:01 AM