Yamaha Virago XV535 Owner's Manual
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Yamaha Virago XV535 Owner's Manual

Virago 1999
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OWNER'S MANUAL
XV535
3BT-28199-E6

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Summary of Contents for Yamaha Virago XV535

  • Page 1 OWNER’S MANUAL XV535 3BT-28199-E6...
  • Page 2 Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all your XV535Õs ad- vantages. The ownerÕs manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and others from trouble and injury.

  • Page 3: Important Manual Information

    This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
  • Page 4 IMPORTANT MANUAL INFORMATION EW000002 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.
  • Page 5 EAU00008 XV535 OWNERÕS MANUAL ©1999 by Yamaha Motor Co., Ltd. 1st Edition, April 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

  • Page 6: Table Of Contents

    EAA30002 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX...

  • Page 8: Give Safety The Right Of Way

    GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY..........1-1...
  • Page 9 GIVE SAFETY THE RIGHT OF WAY EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ig- nore the laws of physics. Regular care and maintenance are essential for preserving your motorcycleÕs value and operating condi- tion.

  • Page 10: Description

    DESCRIPTION Left view ..................... 2-1 Right view................... 2-2 Controls/Instruments ................2-3...

  • Page 11: Left View

    DESCRIPTION EAU00026 Left view 1. Headlight (page 6-27) 6. Rear shock absorber spring 2. Air filter (page 6-10) preload adjusting ring (page 3-9) 3. Rider seat (page 3-7) 7. Main switch (page 3-1) 4. Tool kit (page 6-1) 8. Starter (choke) Ò Ó...

  • Page 12: Right View

    DESCRIPTION Right view 10. Rear turn signal light (page 6-29) 13. Front turn signal light (page 6-29) 11. Sub fuel tank 14. Rear brake pedal (page 3-4) 12. Fuel tank (page 3-5) 15. Battery (page 6-25)
  • Page 13 DESCRIPTION Controls/Instruments 1. Clutch lever (page 3-3) 2. Speedometer (page 3-2) 3. Front brake lever (page 3-4) 4. Throttle grip (page 6-13) 5. Right handlebar switches (page 3-3) 6. Left handlebar switches (page 3-2)

  • Page 14: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS Main switch ..................3-1 Indicator lights ..................3-1 Speedometer..................3-2 Handlebar switches................3-2 Clutch lever ..................3-3 Shift pedal ..................3-4 Front brake lever ................3-4 Rear brake pedal................3-4 Fuel tank cap..................3-5 Fuel ....................3-5 Starter (choke) Ò...

  • Page 15: Instrument And Control Functions

    INSTRUMENT AND CONTROL FUNCTIONS EAU00027 1. Push 1. High beam indicator light Ò Ó EAU00028 Main switch 2. Release 2. Neutral indicator light Ò Ó 3. Turn 3. Turn indicator light Ò Ó The main switch controls the ignition and lighting systems. Its operation is EAU00055 EAU00056 Indicator lights...

  • Page 16: Speedometer

    INSTRUMENT AND CONTROL FUNCTIONS EAU00124 Turn signal switch Ò Ó This model is equipped with self-can- celling turn signals. To signal a right- hand turn, push the switch to the right. To signal a left-hand turn, push the switch to the left. Once the switch is re- leased it will return to the center posi- tion.

  • Page 17: Clutch Lever

    INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch Ò Ó The starter motor cranks the engine when pushing the start switch. EC000005 CAUTION: See starting instructions prior to starting the engine. 1. Engine stop switch 1. Clutch lever EAU00149 2. Lights switch Fuel reserve switch ÒFUELÓ...

  • Page 18: Shift Pedal

    INSTRUMENT AND CONTROL FUNCTIONS 1. Shift pedal 1. Front brake lever 1. Rear brake pedal EAU00157 EAU00158 EAU00162 Shift pedal Front brake lever Rear brake pedal This motorcycle is equipped with a con- The front brake lever is located on the The rear brake pedal is on the right stant-mesh 5-speed transmission.

  • Page 19: Fuel Tank Cap

    INSTRUMENT AND CONTROL FUNCTIONS NOTE: This tank cap cannot be closed unless the key is in the lock. The key cannot be removed if the cap is not locked properly. EW000023 Be sure the cap is properly installed 1. Open 1.

  • Page 20: Starter (Choke) Ò Ó

    INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Always wipe off spilled fuel immedi- ately with a dry and clean soft cloth. Fuel may deteriorate painted surfac- es or plastic parts. EAU00191 1. Starter (choke) Ò Ó 1. Steering lock Recommended fuel: EAU02976 EAU02934 Regular unleaded gasoline with...

  • Page 21: Seats

    INSTRUMENT AND CONTROL FUNCTIONS 1. Seat lock 1. Projection 1. Bolt (´ 2) 2. Open 2. Seat holder Rider seat To install EAU02940 To remove Seats Insert the projection on the rear of the Remove the passenger seat and then Passenger seat seat into the seat holder, and then push remove the two rider seat bolts.

  • Page 22: Helmet Holder

    INSTRUMENT AND CONTROL FUNCTIONS 1. Seat holder (´ 2) 1. Open 2. Projection (´ 2) EAU00260 Helmet holder To install To open the helmet holder, insert the Insert the projections on the front of the key in the lock and turn it as shown. To seat into the seat holders and tighten lock the helmet holder, replace the the bolts.

  • Page 23: Rear Shock Absorber Adjustment

    Turn the ad- sulting in a possible loss of control. justing ring in direction a to increase Yamaha has designed into this mo- spring preload and in direction b to de- torcycle a lockout system to assist crease spring preload.

  • Page 24: Sidestand/Clutch Switch Operation Check

    AND THE ENGINE STOP SWITCH TO EW000045 Ò Ó. If improper operation is noted, con- sult a Yamaha dealer immediately. TRANSMISSION IS IN GEAR AND SIDESTAND IS UP. PULL IN CLUTCH LEVER AND PUSH THE START SWITCH. ENGINE WILL START.

  • Page 26: Pre-Operation Checks

    PRE-OPERATION CHECKS Pre-operation check list..............4-1...

  • Page 27: Pre-Operation Check List

    PRE-OPERATION CHECKS EAU01114 Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or loss of tire pressure could have serious consequences.
  • Page 28 PRE-OPERATION CHECKS ITEM CHECKS PAGE ¥ Check for smooth operation. Sidestand pivot 6-23 ¥ Lubricate if necessary. ¥ Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners Ñ ¥ Tighten if necessary. ¥ Check fuel level. 3-5 ~ 3-6 Fuel tank ¥...

  • Page 30: Operation And Important Riding Points

    OPERATION AND IMPORTANT RIDING POINTS Starting the engine ................5-1 Starting a warm engine ..............5-3 Shifting ....................5-4 Recommended shift points (for Switzerland only)......5-4 Tips for reducing fuel consumption ............ 5-5 Engine break-in .................. 5-5 Parking ....................5-6...

  • Page 31: Operation And Important Riding Points

    The engine their functions. Consult can be started only under one of the Yamaha dealer regarding any following conditions: control or function that you do The transmission is in neutral. not thoroughly understand. The sidestand is up, the transmis-...
  • Page 32 OPERATION AND IMPORTANT RIDING POINTS TURN THE MAIN SWITCH TO ÒONÓ AND THE ENGINE STOP SWITCH TO Ò Ó. IF THE TRANSMISSION IS IN NEUTRAL IF THE TRANSMISSION IS IN GEAR AND THE SIDESTAND IS DOWN, AND THE SIDESTAND IS UP, PUSH THE START SWITCH.

  • Page 33: Starting A Warm Engine

    6. After the engine is warm, turn off the first time. Yamaha dealer to inspect it. the starter (choke) completely. 3. Turn on the starter (choke) and NOTE: completely close the throttle grip.

  • Page 34: Shifting

    OPERATION AND IMPORTANT RIDING POINTS EC000048 EAU02941 Recommended shift points CAUTION: (for Switzerland only) Do not coast for long periods The recommended shift points are with the engine off, and do not shown in the table below. tow the motorcycle a long dis- tance.

  • Page 35: Tips For Reducing Fuel Consumption

    OPERATION AND IMPORTANT RIDING POINTS EAU00424 EAU00436 EAU00444 Tips for reducing fuel Engine break-in 0 ~ 150 km Avoid operation above 1/3 throttle. consumption There is never a more important period Stop the engine and let it cool for 5 to in the life of your motorcycle than the Your motorcycleÕs fuel consumption 10 minutes after every hour of opera-...

  • Page 36: Parking

    The exhaust system is hot. Park the during the break-in period, consult a motorcycle in a place where pedes- Yamaha dealer immediately. trians or children are not likely to touch the motorcycle. Do not park the motorcycle on a slope or soft ground;...

  • Page 38: Periodic Maintenance And Minor Repair

    PERIODIC MAINTENANCE AND MINOR REPAIR Tool kit ..............6-1 Inspecting the brake fluid level......6-20 Periodic maintenance and lubrication....6-2 Brake fluid replacement ........6-21 Spark plugs ............6-5 Cable inspection and lubrication .......6-21 Engine oil............6-7 Throttle cable and grip lubrication.....6-22 Final gear oil ............

  • Page 39: Periodic Maintenance And Minor Repair

    Safety is an obligation of the your motorcycle to a Yamaha dealer motorcycle owner. The maintenance for service. and lubrication schedule chart should...

  • Page 40: Periodic Maintenance And Lubrication

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00473 PERIODIC MAINTENANCE AND LUBRICATION EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) ¥ Check fuel hoses and vacuum hose for cracks or damage. Fuel line Ö...
  • Page 41 PERIODIC MAINTENANCE AND MINOR REPAIR EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) ¥ Check tread depth and for damage. ¥ Replace if necessary. Tires Ö...
  • Page 42 Ö Ö or 24 months (whichever comes first). * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. EAU02970 NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 43: Spark Plugs

    Do not attempt to diagnose such problems yourself. In- stead, take the motorcycle to a Yamaha dealer. You should periodical- ly remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode.
  • Page 44 PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Spark plug: 20 Nm (2.0 mákg) NOTE: If a torque wrench is not available when you are installing a spark plug, a good estimate of the correct torque is 1/4 to 1/2 turn past finger tight. Have the a.

  • Page 45: Engine Oil

    PERIODIC MAINTENANCE AND MINOR REPAIR 2. With the engine stopped, check the oil level through the level win- dow located at the lower part of the left side crankcase cover. NOTE: Wait a few minutes until the oil level settles before checking. 3.
  • Page 46 PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt 1. Oil filter cover 1. O-ring 2. Bolt (´ 3) 2. Oil filter element 3. Remove the drain bolt and drain 4. Remove the oil filter bolts, oil filter NOTE: the oil.

  • Page 47: Final Gear Oil

    PERIODIC MAINTENANCE AND MINOR REPAIR EC000066 2. Remove the oil filler bolt and CAUTION: check the oil level. The oil level Do not put in any chemical addi- should be at the brim of the filler tives. Engine oil also lubricates hole.

  • Page 48: Air Filter

    PERIODIC MAINTENANCE AND MINOR REPAIR Final gear case capacity: 0.19 L Recommended oil: SAE 80 API GL-4 Hypoid gear oil If desired, an SAE 80W90 hypoid gear oil may be used for all conditions. NOTE: 1. Fuel tank 1. Screw 2.
  • Page 49 PERIODIC MAINTENANCE AND MINOR REPAIR 7. Reassemble by reversing the re- moval procedure. EC000082 CAUTION: Make sure the air filter is prop- erly seated in the air filter case. The engine should never be run without the air filter installed. Excessive piston and/or cylin- 1.

  • Page 50: Carburetor Adjustment

    The carburetors are important parts of the engine and require very sophisti- cated adjustment. Most adjustments should be left to a Yamaha dealer who has the professional knowledge and experience to do so. However, the idle speed may be adjusted by the owner as part of routine maintenance.

  • Page 51: Idle Speed Adjustment

    There should be a free play of 3 ~ rection a to increase engine 5 mm at the throttle grip. If the free play speed and in direction b to de- is incorrect, ask a Yamaha dealer to crease engine speed. make this adjustment. Standard idle speed:...

  • Page 52: Valve Clearance Adjustment

    Always check and adjust the tire pres- Maximum load* 2.00 bar) 2.50 bar) Yamaha service technician. sure before operating the motorcycle. * Load is the total weight of cargo, rider, passenger and accessories. EW000082...
  • Page 53 CYCLE. Make sure the total weight the side wall is cracked, contact a regulations of your own country. of the cargo, rider, passenger, and Yamaha dealer immediately and have accessories (fairing, saddlebags, the tire replaced. etc. if approved for this model) does not exceed the maximum load of the motorcycle.

  • Page 54: Wheels

    Brakes, tires, and related wheel If any abnormal condition exists in parts replacement should be a wheel, consult a Yamaha dealer. left to a Yamaha Service Techni- Do not attempt even small repairs cian. to the wheel. If a wheel is de-...

  • Page 55: Clutch Lever Free Play Adjustment

    PERIODIC MAINTENANCE AND MINOR REPAIR 1. Locknut 1. Locknut 1. Adjusting bolt 2. Adjusting bolt 2. Adjusting nut 2. Locknut c. Free play c. Free play If the specified free play cannot be ob- EAU00694 EAU00696 tained, proceed with the following steps. Clutch lever free play Front brake lever free play 4.

  • Page 56: Rear Brake Pedal Height And Free Play Adjustment

    3. Tighten the locknut. Yamaha dealer inspect and EW000105 bleed the system if necessary. It is advisable to have a Yamaha dealer make this adjustment. After adjusting the pedal height ad- just brake pedal free play. The brake pedal height should be ad- justed before adjusting the brake pedal free play.

  • Page 57: Brake Light Switch Adjustment

    If they have almost disap- brake light come on earlier. Turn the peared, ask a Yamaha dealer to re- adjusting nut in direction b to make the place the pads.

  • Page 58: Inspecting The Brake Fluid Level

    If the indicator reaches the wear limit lead to poor brake performance. brakes to become ineffective. line, ask a Yamaha dealer to replace Be careful that water does not en- Before riding, check that the brake fluid the shoes.

  • Page 59: Brake Fluid Replacement

    Yamaha service personnel. EW000112 immediately. Have the Yamaha dealer replace the Have a Yamaha dealer check the following components during periodic Damage to the outer housing of ca- cause if the brake fluid level goes maintenance or when they are dam- bles may lead to internal rusting and down.

  • Page 60: Throttle Cable And Grip Lubrication

    PERIODIC MAINTENANCE AND MINOR REPAIR EAU00773 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated, since the grip must be re- moved to get at the end of the throttle cable.

  • Page 61: Sidestand Lubrication

    Sidestand lubrication from the front fork. Lubricate the sidestand pivoting point and metal-to-metal contact surfaces. Check that the sidestand moves up and down smoothly. Recommended lubricant: Engine oil EW000113 If the sidestand does not move smoothly, consult a Yamaha dealer. 6-23...

  • Page 62: Steering Inspection

    If EC000098 any free play can be felt, ask a Yamaha CAUTION: dealer to inspect and adjust the steer- ing. Inspection is easier if the front If any damage or unsmooth move- wheel is removed.

  • Page 63: Battery

    PERIODIC MAINTENANCE AND MINOR REPAIR EC000099 EW000116 CAUTION: Battery electrolyte is poisonous and When inspecting the battery, be dangerous, causing severe burns, sure the breather hose is routed cor- etc. It contains sulfuric acid. Avoid rectly. If the breather hose is posi- contact with skin, eyes or clothing.
  • Page 64 PERIODIC MAINTENANCE AND MINOR REPAIR Battery storage When the motorcycle will not be used for a month or longer, re- move the battery, fully charge it and store it in a cool, dry place. Completely recharge the battery before reinstalling. If the battery will be stored for longer than two months, check the 1.

  • Page 65: Fuse Replacement

    Install a new fuse of the specified amperage. Turn on the switches and check if the electrical de- vice operates. If the fuse immediately blows again, consult a Yamaha dealer. 6-27...
  • Page 66 4. Put a new bulb into position and secure it in place with the bulb 5. Install the bulb cover, connector holder. and headlight unit. Ask a Yamaha dealer to adjust the headlight beam if necessary. 6-28...

  • Page 67: Turn Signal And Taillight Bulb Replacement

    EAU00855 Turn signal and taillight bulb If your motorcycle requires any repair, counterclockwise. bring it to a Yamaha dealer. The skilled replacement 3. Place a new bulb in the socket. technicians at a Yamaha dealership 1. Remove the screws and the lense.

  • Page 68: Troubleshooting Chart

    Remove spark plugs and check electrode. Engine doesnÕt start, go to battery Dry. Ask a Yamaha dealer to inspect. check. 4. Battery Engine turns over Battery good. quickly. Engine doesnÕt start, ask a Yamaha Use the electric starter.

  • Page 70: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE Care ....................7-1 Storage....................7-4...

  • Page 71: Motorcycle Care And Storage

    MOTORCYCLE CARE AND STORAGE EAU01521 Care Before cleaning Cleaning 1. Cover up the muffler outlets with After normal use The exposure of its technology makes plastic bags. Remove dirt with warm water, a neutral a motorcycle charming but also vulner- 2.
  • Page 72 MOTORCYCLE CARE AND STORAGE ECA00010 Do not use any harsh chemical For motorcycles equipped with CAUTION: products on plastic parts. Be a windshield: Do not use strong Avoid using strong acidic wheel sure to avoid using cloths or cleaners or hard sponges as cleaners, especially on spoked sponges which have been in they will cause dulling or...
  • Page 73 MOTORCYCLE CARE AND STORAGE EWA00001 After cleaning 1. Clean your motorcycle with cold water and soap after the engine 1. Dry the motorcycle with a chamois Make sure that there is no oil or wax has cooled down. or an absorbing cloth. on the brakes and tires.
  • Page 74 NOTE: ÒOFFÓ position: Turn the fuel cock To prevent corrosion, avoid Consult a Yamaha dealer for advice on to ÒOFFÓ. damp cellars, stables (because what products to use. 4. Fill up the fuel tank and add fuel...
  • Page 75 MOTORCYCLE CARE AND STORAGE a. Remove the spark plug caps and 6. Lubricate all control cables and 9. Remove the battery and fully spark plugs. the pivoting points of all levers and charge it. Store it in a cool, dry b.

  • Page 76: Specifications

    SPECIFICATIONS Specifications ..................8-1 HOW TO USE THE CONVERSION TABLE ........8-5...

  • Page 77: Specifications

    SPECIFICATIONS EAU01038 Specifications Model XV535 Engine oil Dimensions Type -20û -10û 0û 10û 20û 30û 40û 50ûC Overall length 2,225 mm (except for CH, S, SF, N) SAE 10W/30 2,250 mm (for CH, S, SF, N) SAE 10W/40 Overall width...
  • Page 78 SPECIFICATIONS Final gear oil Transmission type Constant mesh 5-speed Type SAE 80 API ÒGL-4Ó hypoid gear Operation Left foot operation Gear ratio Quantity 0.19 L 2.714 Air filter Dry type element 1.900 Fuel 1.458 Type Regular unleaded gasoline 1.167 Fuel tank capacity 13.5 L 0.967 Reserve amount...
  • Page 79 SPECIFICATIONS Maximum load* 220 kg (except for CH, A) Rear 218 kg (for CH, A) Type Drum brake Air pressure (cold tire) Operation Right foot operation Up to 90 kg load* Suspension Front 200 kPa (2.00 kg/cm , 2.00 bar) Front Rear 225 kPa (2.25 kg/cm...
  • Page 80 SPECIFICATIONS Bulb voltage, wattage ´ quantity Headlight 12 V, 60/55 W ´ 1 Auxiliary light 12 V, 4 W ´ 1 (except for GB) 12 V, 3.4 W ´ 1 (for GB) Tail/brake light 12 V, 5/21 W ´ 2 Front ßasher light 12 V, 21 W ´...

  • Page 81: How To Use The Conversion Table

    SPECIFICATIONS EAU01064 HOW TO USE THE CONVERSION TABLE CONVERSION TABLE All specification data in this manual are listed in SI and METRIC TO IMPERIAL METRIC UNITS. Metric unit Multiplier Imperial unit Use this table to convert METRIC unit data to IMPERIAL mákg 7.233 ftálb...

  • Page 82: Consumer Information

    CONSUMER INFORMATION Identification number records............. 9-1 Key identification number..............9-1 Vehicle identification number ............. 9-1 Model label..................9-2...

  • Page 83: Consumer Information

    Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is sto- len. 1. KEY IDENTIFICATION 1.

  • Page 84: Model Label

    The model label is affixed to the frame under the seat. (See page 3-7 for seat removal procedures.) Record the infor- mation on this label in the space pro- vided. This information will be needed to order spare parts from your Yamaha dealer.

  • Page 85: Front Brake Lever

    INDEX Front brake lever free play Neutral indicator light ....... 3-1 adjustment ........6-17 Turn indicator light ......3-1 Air filter ..........6-10 Front fork inspection ......6-23 Inspecting the brake fluid level .... 6-20 Fuel ............3-5 Battery ..........6-25 Fuel reserve switch ........ 3-3 Key identification number ......
  • Page 86 INDEX Turn signal and taillight bulb replacement ........6-29 Seats ............. 3-7 Turn signal switch ........3-2 Shift pedal ..........3-4 Shifting ........... 5-4 Sidestand ..........3-9 Valve clearance adjustment ....6-14 Sidestand lubrication ......6-23 Vehicle identification number ....9-1 Sidestand/clutch switch operation check ..........
  • Page 87 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 99 · 5 - 0.3...

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