2001 YAMAHA XV535 air suspension

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
6-16
6
l
Adjust the suspension and tire
air pressure with regard to the
load.
l
Check the tire condition and air
pressure before each ride.
@
Tire inspection
The tires must be checked before each
ride. If the center tread depth reaches
the specified limit, if the tire has a nail
or glass fragments in it, or if the side-
wall is cracked, have a Yamaha dealer
replace the tire immediately.CE-08ENOTE:@ The tire tread depth limits may differ
from country to country. Always comply
with the local regulations. @
EW000079
WARNING
@ l
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
motorcycle with excessively
worn tires decreases riding sta-
bility and can lead to loss of
control.
l
The replacement of all wheel-
and brake-related parts, includ-
ing the tires, should be left to a
Yamaha dealer, who has the
necessary professional knowl-
edge and experience.
@
1. Sidewall
a. Tire tread depthMinimum tire tread depth
(front and rear)1.6 mm
E_3bt.book Page 16 Thursday, September 7, 2000 10:01 AM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-26
6
EAU00790
Lubricating the rear
suspension The pivoting points of the rear suspen-
sion must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart. Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)Recommended lubricant:
Molybdenum disulfide grease
E_3bt.book Page 26 Thursday, September 7, 2000 10:01 AM

SPECIFICATIONS
8-3
8
Maximum load* 220 kg (except for A)
218 kg (for A)
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 200 kPa (2.00 kg/cm
2, 2.00 bar)
Rear 225 kPa (2.25 kg/cm2, 2.25 bar)
90 kg–maximum*
Front 200 kPa (2.00 kg/cm2, 2.00 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Spoke wheel
Size 19 ´ MT 1.85
Rear
Type Spoke wheel
Size 15 M/C ´ MT 3.00
Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4 or DOT 3Rear
Type Drum brake
Operation Right foot
Suspension
Front Telescopic fork
Rear Swingarm
Springs/shock absorbers
Front Coil spring / oil damper
Rear Coil spring / oil damper
Wheel travel
Front 150 mm
Rear 85 mm
Electrical system
Ignition system T.C.I. (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 24 A @ 5,000 r/min
Battery
Model GM12AZ-3A-2
Voltage, capacity 12 V, 12 Ah
Headlight typeQuartz bulb (halogen)
E_3bt.book Page 3 Thursday, September 7, 2000 10:01 AM