2001 YAMAHA XV535 steering wheel

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

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
6-28
6 2. Hold the lower ends of the front
fork legs and try to move them for-
ward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the
steering.
EAU01144
Checking the wheel bearingsThe front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
E_3bt.book Page 28 Thursday, September 7, 2000 10:01 AM

INDEX
Spark plugs, checking ............................. 6-5
Specifications .......................................... 8-1
Speedometer unit .................................... 3-2
Starter (choke) lever ................................ 3-6
Starting a cold engine .............................. 5-1
Starting a warm engine ............................ 5-2
Start switch .............................................. 3-3
Steering, checking ................................. 6-27
Steering lock............................................ 3-7
Storage.................................................... 7-4
Supporting the motorcycle ..................... 6-33
Suspension (rear), lubricating ................ 6-26TThrottle cable free play, adjusting .......... 6-14
Throttle grip and cable, checking and
lubricating............................................ 6-24
Tires ...................................................... 6-15
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-37
Troubleshooting chart ............................ 6-38
Turn signal indicator light ......................... 3-1
Turn signal or tail/brake light bulb,
replacing ............................................. 6-33
Turn signal switch .................................... 3-2VValve clearance, adjusting ..................... 6-14
Vehicle identification number ................... 9-1
WWheel bearings, checking ..................... 6-28
Wheel (front) ......................................... 6-34
Installing .......................................... 6-35
Removing ........................................ 6-34
Wheel (rear) .......................................... 6-35
Installing .......................................... 6-37
Removing ........................................ 6-35
Wheels .................................................. 6-17
E_3bt.book Page 2 Thursday, September 7, 2000 10:01 AM