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XV 535 DX Virago
Yamaha XV 535 DX Virago Manuals
Manuals and User Guides for Yamaha XV 535 DX Virago. We have
1
Yamaha XV 535 DX Virago manual available for free PDF download: Service Manual
Yamaha XV 535 DX Virago Service Manual (212 pages)
Brand:
Yamaha
| Category:
Motorcycle
| Size: 40.22 MB
Table of Contents
General Information
1
Parts Replacement
1
Engine Serial Numbers
2
General Specifications
2
Emergency Troubleshooting
4
Engine Starting/Performance
5
Ignition System
5
Periodic Lubrication, Maintenance and Tune-Up
6
Routine Checks
6
Engine Oil Level
6
Tire Pressure
6
Maintenance Intervals
7
Tires and Wheels
7
Battery
7
Removal/Installation and Electrolyte Level Check
7
New Battery Installation
9
Periodic Lubrication
10
Engine Oil Level Check
10
Engine Oil and Filter Change
10
Front Fork Oil Change
12
Periodic Maintenance
13
Front Disc Brake
13
Disc Brake Fluid Level
13
Disc Brake Pad Wear
14
Front Brake Lever Adjustment
14
Rear Brake Pedal Height Adjustment
15
Gearshift Pedal Adjustment
15
Clutch Adjustment
15
Throttle Operation/Adjustment
16
Air Cleaner Removal/Installation
17
Front/Rear Suspension Check
18
Tune-Up
19
Tools
20
Air Cleaner Element
20
Valve Adjustment
20
TDC for Rear/Front Cylinder
22
Firing Range for Rear Cylinder
22
Correct Spark Plug Heat Range
23
Ignition Timing
24
Carburetor Synchronization
25
Carburetor Idle Speed Adjustment
25
Maintenance Schedule
25
Tire Inflation Pressure (Cold)
26
Recommended Lubricants
26
Approximate Refill Capacities
27
Tune up Specifications
27
Engine Principles
28
Servicing Engine in Frame
28
Stroke Principles
29
Engine Removal/Installation
30
Cylinder Heads and Camshaft Removal
34
Camshaft Inspection
39
Cylinder Head Inspection
40
Cylinder Head Installation
41
Valves and Valve Components Removal/Assembly
45
Valves and Valve Components Inspection
46
Valves and Valve Components Installation
47
Valve Spring Height
47
Rocker Arm Assemblies
48
Valve Guide Replacement
48
Valve Seat Reconditioning
48
Valve Lapping
48
Rocker Arm Removal/Inspection/Installation
49
Cylinder Removal/Inspection
50
Cylinder Installation
51
Piston Removal/Installation
52
Piston Inspection
53
Piston Clearance Measurement
54
Piston Ring Removal/Installation
55
Oil Pump Removal/Installation
56
Oil Pump Disassembly/Inspection/Assembly
57
Oil Strainer Removal/Inspection/Installation
59
Primary Drive Gear Removal/Installation
60
Camshaft Drive Chain and Damper
62
Front/Rear Cylinder Removal/Installation
62
Crankcase Disassembly
63
Front/Rear Cylinder Inspection
63
Crankcase Inspection
64
Crankcase Bearings Inspection/Replacement
64
Crankcase Bearings Assembly
66
Crankshaft and Connecting Rods Removal/Installation
67
Connecting Rod Inspection
68
Connecting Rod Bearing and Oil Clearance Measurement
68
Connecting Rod Side Clearance Measurement
70
Crankshaft Inspection
70
Crankshaft Bearing and Oil Clearance Measurement
70
Middle Drive Gear Removal/Installation
71
Starter Clutch and Reduction Gears Removal/Installatin
73
Middle Drive Gear Inspection
73
Break-In
74
Starter Clutch and Reduction Gears Inspection
74
500-Mile Service
75
Engine Specifications
75
Engine Tightening Torque
77
Clutch Removal
78
Clutch Parts List
79
Clutch Inspection
81
Clutch Installation
84
Clutch Mechanism Free Play Adjustment
86
Clutch Cable Replacement
87
Shift Mechanism
87
Shifter Assembly
88
Shifter Removal/Inspection/Installation
89
Transmission Removal/Installation
91
Transmission Parts List
91
Main Shaft Disassembly/Assembly
92
Drive Axle Disassembly/Assembly
94
Drive Axle Inspection
95
Shift Drum and Forks Removal/Installation
97
Shift Drum and Forks Inspection
99
Clutch Specifications
99
Clutch Tightening Torque
99
Fuel, Emission Control and Exhaust Systems
100
Carburetor Removal/Installation
100
Carburetor Assembly Separation/Reassembly
103
Carburetor Exploded View
104
Individual Carburetor Disassembly/Assembly
105
Individual Carburetor Cleaning and Inspection
108
Carburetor Adjustments
110
Coasting Enricher System
110
Fuel Level Measurement
110
Fuel Level Inspection/Adjustment
111
Throttle Cable Replacement
112
Throttle Cable Installation
113
Fuel Shutoff Valve Troubleshooting/Removal/Installation
113
Fuel Filter Removal/Installation
114
Fuel Pump Removal/Installation
114
Shutoff Valve Parts List
114
Fuel Tanks
115
Sub-Fuel Tank
115
Main Fuel Tank Removal/Installation
116
Crankcase Breather System
117
Evaporate Emission Control Parts Replacement
117
Evaporate Emission Control Inspection/Replacement
117
Roll-Over Valve Replacement
117
Air Injection System Removal/Installation
118
Canister and Hose Replacement
118
Evaporative Emission Control
118
Air Injection System View
119
Air Injection System Layout
120
Air Injection System Components
121
Exhaust System Removal/Installation
123
Exhaust System Inspection/Maintenance
124
Carburetor Specifications
125
Testing Charging System
126
Charging System Wiring Diagram
127
Alternator
128
Stator Checks
128
Stator Removal/Installation
129
Stator Inspection
130
Flywheel (Rotor) Removal/Installation
130
Voltage Regulator/Rectifier
132
Ignition System Troubleshooting
132
Flywheel (Rotor) Testing
132
Ignition Spark Test
132
Ignition System Wiring Diagram
133
Ignition System Diagnosis
134
Pickup Coil Testing
135
Pickup Coil Removal/Installation
135
Ignition Coils Testing
136
Ignition Coil Removal/Installation
138
Ignitor Unit Check
138
Ignitor Unit Removal/Installation
138
Starting System
139
Starter Motor Removal/Installation/Disassembly/Assembly
139
Starting System Wiring Diagram
140
Starter Motor Parts Location
141
Armature Condition
142
Starter Relay Removal/Installation
144
Starting Circuit Cut-Off/Sidestand Relay Testing
144
Lighting System
145
Starting Circuit Neutral Switch Testing
145
Headlight Replacement/Adjustment
146
Speedometer Illumination Bulb Replacement
146
Front/Rear Brake Light Switch Replacement
147
Rear Brake Light Switch Adjustment
147
Sidestand Switch Replacement
147
Fuel Pump Testing
148
Flasher Relay Replacement
148
Fuel Pump Circuit
149
Horn Removal/Installation/Testing
152
Fuses
152
Fuel Pump Testing/Connector
152
Fuel Reserve Switch
152
Electrical Specifications
153
Starter Troubleshooting
153
Replacement Bulbs
153
Front Suspension and Steering
154
Front Wheel Removal/Installation
154
Front Wheel Inspection
155
Front Wheel
156
Front Hub Disassembly/Inspection
157
Handlebar Removal/Installation
158
Front Hub Assembly
158
Steering Head Disassembly
159
Steering Stem
160
Steering Head Inspection
161
Bearing Race Replacement/Assembly
161
Front Forks Removal/Installation
162
Steering Stem Adjustment
162
Steering Stem Disassembly
163
Front Fork
164
Steering Stem Inspection/Assembly
167
Front Suspension and Steering Specifications
170
Front Suspension Tightening Torques
170
Rear Wheel Removal/Installation
171
Rear Wheel Parts List
172
Rear Hub Disassembly
173
Rear Wheel Inspection
173
Rear Hub Inspection
174
Shaft Drive Removal/Installation
175
Rear Hub Assembly
175
Rear Swing Arm
176
Shaft Drive Disassembly/Inspection/Troubleshooting
176
Swing Arm Parts Location
176
Rear Swing Arm Removal/Installation/Inspection
177
Shock Absorbers Removal/Inspection/Installation
179
Rear Suspensions Specifications
180
Rear Suspension Tightening Torques
180
Brakes
181
Master Cylinder Removal/Installation
182
Master Cylinder Disassembly
183
Master Cylinder Parts Location
183
Master Cylinder Inspection
184
Master Cylinder Assembly
185
Front Brake Pad Replacement
186
Brake Caliper Parts List
186
Front Caliper Removal/Installation
188
Caliper Rebuilding
189
Caliper Inspection
190
Front Brake Hose Replacement
191
Front Brake Disc Removal/Installation/Inspection
192
Rear Brake Pedal Assembly Removal/Installation
193
Brake Specifications
194
Brake Tightening Torques
194
Index
195
XV535T/TC/U/UC/W/WS Wiring Diagram
198
XV535A/AC/E/EC Wiring Diagram
200
XV535 (1988-1991 UK) Wiring Diagram
202
XV535 (1992-ON UK) Wiring Diagram
204
XV535 (French and German) Wiring Diagram
206
Contents
208
Product View
210
Maintenance Log
211
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