2001 YAMAHA XV535 warning light

PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-24
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-15–6-17
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-25
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-25
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-25–6-26
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.—
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-10
Battery• Check fluid level.
• Fill with distilled water if necessary.6-29–6-30 ITEM CHECKS PAGE
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5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@ l
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
l
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
l
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU02997*
Starting a cold engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:l
The transmission is in the neutral
position.
l
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
@ l
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-11.
l
Never ride with the sidestand
down.
@
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
2. Shift the transmission into the neu-
tral position.NOTE:@ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit. @3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6 for starter (choke) opera-
tion.)
4. Start the engine by pushing the
start switch.NOTE:@ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:@ Make sure that the O-ring is properly
seated. @7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
EC000067
CAUTION:@ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. @9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU03714
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the final gear oil level must be
checked and the oil changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
EW000066
WARNING
_ l
Make sure that no foreign mate-
rial enters the final gear case.
l
Make sure that no oil gets on
the tire or wheel.
_
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
2.6 L
With oil filter element
replacement:
2.8 L
Total amount (dry engine):
3.2 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 6. Pull the air filter element out.
7. Lightly tap the air filter element to
remove most of the dust and dirt,
and then blow the remaining dirt
out with compressed air as shown.
If the air filter element is damaged,
replace it.
8. Insert the air filter element into the
air filter case.
EC000082
CAUTION:_ l
Make sure that the air filter ele-
ment is properly seated in the
air filter case.
l
The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
become excessively worn.
_9. Place the air filter case cover in the
original position, and then install
the screw.
10. Install the fuel tank by installing the
bolts.
EW000131
WARNING
_ Make sure that the fuel hoses and
vacuum hose are properly connect-
ed and routed, and not pinched. Re-
place any damaged hoses. _
EC000086
CAUTION:_ When installing the fuel tank bolts,
make sure that the washers, rubber
dampers and spacers are posi-
tioned properly. _11. Install the seats.
1. Air filter element
1. Washer
2. Rubber damper
3. Spacer
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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.
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU01406
To install the rear wheel
1. Apply a light coating of lithium-
soap-based grease to the splines
of the final gear case and wheel
hub.
2. Install the wheel by inserting the
wheel axle.
3. Install the brake rod onto the brake
camshaft lever, and then install
the brake pedal free play adjusting
nut onto the brake rod.
4. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and the nut.
5. Install the rear wheel axle pinch
bolt.6. Lower the rear wheel so that it is
on the ground.
7. Tighten the axle nut, pinch bolt
and brake torque rod nut to the
specified torques.
8. Install the brake torque rod cotter
pin.
EW000124
WARNING
_ Always use a new cotter pin. _9. Adjust the brake pedal free play.
(See page 6-20 for brake pedal
free play adjustment procedures.)
EW000103
WARNING
_ After adjusting the brake pedal free
play, check the operation of the
brake light. _
EAU01008
TroubleshootingAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
Tightening torques:
Axle nut:
107 Nm (10.7 m·kg)
Rear wheel axle pinch bolt:
16 Nm (1.6 m·kg)
Brake torque rod nut:
20 Nm (2.0 m·kg)
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