2001 YAMAHA XV535 brake pads

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
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.ÖÖÖÖ
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6*Battery• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.ÖÖÖÖ Ö
7Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
8*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Rear brake• Check operation and adjust brake pedal freeplay.ÖÖÖÖÖ Ö
• Replace brake shoes. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-21
6
EAU00713
Adjusting the rear brake light
switchThe rear brake light switch, which is ac-
tivated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in place. To
make the brake light come on earlier,
turn the adjusting nut in direction
a. To
make the brake light come on later,
turn the adjusting nut in direction
b.
EAU00720
Checking the front brake pads
and rear brake shoes The front brake pads and the rear
brake shoes must be checked for wear
at the intervals specified in the periodic
maintenance and lubrication chart.
EAU01119
Front brake pads
Each front brake pad is provided with
wear indicator grooves, which allow
you to check the brake pad wear with-
out having to disassemble the brake.
To check the brake pad wear, check
the wear indicator grooves. If a brake
pad has worn to the point that the wear
indicators have almost disappeared,
have a Yamaha dealer replace the
brake pads as a set.
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Front brake pad wear indicator groove (´ 2)Front
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU00727
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
EAU00732
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage.Observe these precautions:
l
When checking the fluid level,
make sure that the top of the mas-
ter cylinder is level by turning the
handlebars.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
NOTE:@ If DOT 4 is not available, DOT 3 can be
used. @l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
1. Rear brake shoe wear limit
2. Rear brake shoe wear indicatorRear
1. Minimum level mark
Recommended brake fluid: DOT 4
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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
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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
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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
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10-INDEXAAir filter element, cleaning ...................... 6-11BBattery ................................................... 6-29
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-25
Brake fluid, changing ............................. 6-23
Brake fluid level, checking...................... 6-22
Brake lever...............................................3-4
Brake lever free play, adjusting .............. 6-19
Brake light switch, adjusting ................... 6-21
Brake pads and shoes, checking ........... 6-21
Brake pedal..............................................3-4
Brake pedal position and free play,
adjusting .............................................. 6-19CCables, checking and lubricating............ 6-23
Carburetors, adjusting............................ 6-13
Care.........................................................7-1
Clutch lever ..............................................3-3
Clutch lever free play, adjusting ............. 6-18
Conversion table ......................................8-5DDimmer switch .........................................3-2
EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-7
Engine stop switch................................... 3-3FFinal gear oil ............................................ 6-9
Front fork, checking ............................... 6-27
Fuel ......................................................... 3-5
Fuel consumption, tips for reducing ......... 5-4
Fuel reserve switch.................................. 3-3
Fuel tank cap ........................................... 3-5
Fuses, replacing .................................... 6-31HHandlebar switches ................................. 3-2
Headlight bulb, replacing ....................... 6-31
Helmet holder .......................................... 3-9
High beam indicator light ......................... 3-1
Horn switch ............................................. 3-2IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-13
Ignition circuit cut-off system.................. 3-10
Indicator lights ......................................... 3-1KKey identification number ........................ 9-1
LLight switch ..............................................3-3MMain switch ..............................................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-1PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-2
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seats .......................................................3-7
Passenger seat...................................3-7
Rider seat ...........................................3-8
Shifting .....................................................5-3
Shift pedal ................................................3-4
Shift points (for Switzerland only) .............5-3
Shock absorber assemblies, adjusting .....3-9
Sidestand ...............................................3-10
Sidestand, checking and lubricating .......6-25
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM