2001 YAMAHA XV535 engine

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.
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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
6-24
6
EAU03209
Checking and lubricating the
throttle grip and cableThe operation of the throttle grip and
the condition of the throttle cable
should be checked before each ride,
and the cable should be lubricated or
replaced if necessary.NOTE:@ Since the throttle grip must be removed
to access the throttle cable end, the
throttle grip and the cable should al-
ways be lubricated at the same time. @1. Remove the throttle grip by remov-
ing the screws.
2. Disconnect the throttle cable, hold
it up, and then apply several drops
of oil to the cable end, allowing it to
trickle into the sheath.
3. Connect the throttle cable, and
then grease the inside of the throt-
tle grip housing.
4. Grease the metal-to-metal contact
surface of the throttle grip, and
then install the grip by installing
the screws.Recommended lubricant:
Throttle cable:
Engine oil
Throttle grip housing and grip:
Lithium-soap-based grease
(all-purpose grease)
E_3bt.book Page 24 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
6-33
6
EAU00855
Replacing a turn signal light
bulb or the tail/brake light
bulb1. Remove the lens by removing the
screws.2. Remove the defective bulb by
pushing it in and turning it counter-
clockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clock-
wise until it stops.
4. Install the lens by installing the
screws.
EC000108
CAUTION:@ Do not overtighten the screws, oth-
erwise the lens may break. @
EAU01579
Supporting the motorcycle Since this model is not equipped with a
centerstand, follow these precautions
when removing the front and rear
wheel or performing other mainte-
nance requiring the motorcycle to
stand upright. Check that the motor-
cycle is in a stable and level position
before starting any maintenance. A
strong wooden box can be placed un-
der the engine for added stability.
To service the front wheel
1. Stabilize the rear of the motorcycle
by using a motorcycle stand or, if
an additional motorcycle stand is
not available, by placing a jack un-
der the frame in front of the rear
wheel.
2. Raise the front wheel off the
ground by using a motorcycle
stand.
1. Screw (´ 2)
1. Tail/brake light bulb (´ 2)
E_3bt.book Page 33 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
EAU01562
Troubleshooting chart
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wet
Dry
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.Open throttle halfway and operate
the electric starter.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the electrolyte and battery
lead connections, and charge the
battery if necessary.The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the compressoin.
E_3bt.book Page 38 Thursday, September 7, 2000 10:01 AM

7-1
7
EAU03412
7-MOTORCYCLE CARE AND STORAGECare While the open design of a motorcycle
reveals the attractiveness of the tech-
nology, it also makes it more vulnera-
ble. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go un-
noticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.Before cleaning
1. Cover the muffler outlets with plas-
tic bags after the engine has
cooled down.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.Cleaning
ECA00010
CAUTION:@ l
Avoid using strong acidic wheel
cleaners, especially on spoked
wheels. If such products are
used on hard-to-remove dirt, do
not leave the cleaner on the af-
fected area any longer than in-
structed. Also, thoroughly rinse
the area off with water, immedi-
ately dry it, and then apply a
corrosion protection spray.
l
Improper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM

MOTORCYCLE CARE AND STORAGE
7-2
7
l
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
l
Do not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel and swing-
arm bearings, fork and brakes),
electric components (couplers,
connectors, instruments,
switches and lights), breather
hoses and vents.
l
For motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure that it does
not leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
@After normal useRemove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.After riding in the rain, near the sea or
on salt-sprayed roadsSince sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.NOTE:@ Salt sprayed on roads in the winter may
remain well into spring. @1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
ECA00012
CAUTION:@ Do not use warm water since it in-
creases the corrosive action of the
salt. @2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nick-
el-plated, surfaces to prevent
corrosion.
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM