xv535 owner's manual

3BT-28199-E7

OWNERS MANUAL

XV535PRINTED IN JAPAN2000 7 - 0.2 1 CR

(E)PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

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EAU03338 INTRODUCTION

Welcome to the Yamaha world of motorcycling!

As the owner of an XV535, you are benefiting from Yamahas vast experience andnewest technology regarding the design and manufacture of high-quality products,which have earned Yamaha a reputation for dependability.

Please take the time to read this manual thoroughly, so as to enjoy all advantages ofyour XV535. The owners manual does not only instruct you in how to operate,inspect and maintain your motorcycle, but also in how to safeguard yourself and oth-ers from trouble and injury.In addition, the many tips given in this manual will help keep your motorcycle in thebest possible condition. If you have any further questions, do not hesitate to contactyour Yamaha dealer.

The Yamaha team wishes you many safe and pleasant rides. So, remember to putsafety first!

E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM


EAU00005IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY ISINVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to themotorcycle operator, a bystander, or a person inspecting or repairing themotorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to themotorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

NOTE:@

l This manual should be considered a permanent part of this motorcycle and should remainwith it even if the motorcycle is subsequently sold.

l Yamaha continually seeks advancements in product design and quality. Therefore, whilethis manual contains the most current product information available at the time of printing,there may be minor discrepancies between your motorcycle and this manual. If you haveany questions concerning this manual, please consult your Yamaha dealer.

@



IMPORTANT MANUAL INFORMATIONEW000002

WARNING@

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATINGTHIS MOTORCYCLE. @



IMPORTANT MANUAL INFORMATION

EAU03337

XV535OWNERS MANUAL

2000 by Yamaha Motor Co., Ltd.1st Edition, July 2000All rights reserved.

Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd.is expressly prohibited.

Printed in Japan.



TABLE OF CONTENTS

1 GIVE SAFETY THE RIGHT OF WAY 1

2 DESCRIPTION 2

3 INSTRUMENT AND CONTROL FUNCTIONS 3

4 PRE-OPERATION CHECKS 4

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

8 SPECIFICATIONS 8

9 CONSUMER INFORMATION 9

INDEX

EAU00009



GIVE SAFETY THE RIGHT OF WAY

1

GIVE SAFETY THE RIGHT OF WAY................................................. 1-1



11-1

EAU000211-GIVE SAFETY THE RIGHT OF WAY

Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power andfreedom. However, they also impose certain limits, which you must accept; even the best motorcycledoes not ignore the laws of physics.

Regular care and maintenance are essential for preserving value and operating condition of yourmotorcycle. Moreover, what is true for the motorcycle is also true for the rider: good performancedepends on being in good shape. Riding under the influence of medication, drugs and alcohol is, ofcourse, out of the question. Motorcycle ridersmore than car driversmust always be at their mentaland physical best. Under the influence of even small amounts of alcohol, there is a tendency to takedangerous risks.

Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers andpassengers. Always wear a complete motorcycle suit (whether made of leather or tear-resistantsynthetic materials with protectors), sturdy boots, motorcycle gloves and a properly fitting helmet.Optimum protective wear, however, should not encourage carelessness. Although full-coveragehelmets and suits, in particular, create an illusion of total safety and protection, motorcyclists willalways be vulnerable. Riders who lack critical self-control run the risk of going too fast and are apt totake chances. This is even more dangerous in wet weather. The good motorcyclist rides safely,predictably and defensivelyavoiding all dangers, including those caused by others.

Enjoy your ride!



DESCRIPTION

2

Left view ............................................................................................. 2-1Right view........................................................................................... 2-2Controls and instruments ................................................................... 2-3



2-1

2

EAU000262-DESCRIPTIONLeft view

1. Headlight (page 6-31)2. Air filter element (page 6-11)3. Rider seat (page 3-8)4. Owners tool kit (page 6-1)5. Helmet holder (page 3-9)6. Passenger seat (page 3-7)

7. Shock absorber spring preload adjusting ring (page 3-9)

8. Main switch (page 3-1)9. Starter (choke) lever (page 3-6)

10. Shift pedal (page 3-4)



DESCRIPTION

2-2

2

Right view

11. Rear turn signal light (page 6-33)12. Fuel sub-tank13. Fuel tank (page 3-5)

14. Front turn signal light (page 6-33)15. Brake pedal (page 3-4)16. Battery (page 6-29)



DESCRIPTION

2-3

2

Controls and instruments

1. Clutch lever (page 3-3)2. Speedometer unit (page 3-2)3. Brake lever (page 3-4)4. Throttle grip (page 6-14)5. Right handlebar switches (page 3-3)6. Left handlebar switches (page 3-2)



INSTRUMENT AND CONTROL FUNCTIONS

3

Main switch ........................................................................................ 3-1Indicator lights .................................................................................... 3-1Speedometer unit .............................................................................. 3-2Handlebar switches............................................................................ 3-2Clutch lever ........................................................................................ 3-3Shift pedal .......................................................................................... 3-4Brake lever ......................................................................................... 3-4Brake pedal ........................................................................................ 3-4Fuel tank cap ..................................................................................... 3-5Fuel .................................................................................................... 3-5Starter (choke) lever........................................................................... 3-6Steering lock ..................................................................................... 3-7Seats ................................................................................................. 3-7Helmet holder..................................................................................... 3-9Adjusting the shock absorber assemblies ......................................... 3-9Sidestand ......................................................................................... 3-10Ignition circuit cut-off system............................................................ 3-10



3-1

3

EAU000273-INSTRUMENT AND CONTROL FUNCTIONS

EAU00028

Main switch The main switch controls the ignitionand lighting systems. The various mainswitch positions are described below.

EAU00036

ONAll electrical systems are supplied withpower, and the engine can be started.The key cannot be removed.

EAU00038

OFFAll electrical systems are off. The keycan be removed.

EAU00055

P (Parking)The taillight and auxiliary light are on,but all other electrical systems are off.The key can be removed.The key must be pushed in, and thenreleased before it can be turned to P.

ECA00043

CAUTION:@

Do not use the parking position foran extended length of time, other-wise the battery may discharge. @

EAU00056

Indicator lights

EAU00063

High beam indicator light This indicator light comes on when thehigh beam of the headlight is switchedon.

EAU00061

Neutral indicator light This indicator light comes on when thetransmission is in the neutral position.

EAU00057

Turn signal indicator light This indicator light flashes when the turnsignal switch is pushed to the left or right.

1. Push.2. Release.3. Turn.

1. High beam indicator light 2. Neutral indicator light 3. Turn signal indicator light




3-2

3

EAU00095

Speedometer unit The speedometer unit is equipped witha speedometer, an odometer and atripmeter. The speedometer showsriding speed. The odometer shows thetotal distance traveled. The tripmetershows the distance traveled since itwas last set to zero with the reset knob.The tripmeter can be used to estimatethe distance that can be traveled with afull tank of fuel. This information will en-able you to plan future fuel stops.

EAU00118

Handlebar switches

EAU00119

Pass switch Press this switch to flash the headlight.

EAU00121

Dimmer switch Set this switch to for the highbeam and to for the low beam.

EAU00124

Turn signal switchTo signal a right-hand turn, push thisswitch to the right. To signal a left-handturn, push this switch to the left. Whenreleased, the switch returns to the cen-ter position.Since this model is equipped with a self-canceling system, the turn signal lightswill self-cancel after the motorcycle hastraveled both about 150 m and for ap-proximately 15 seconds. However, theturn signal lights can also be canceledmanually by pushing the switch in afterit has returned to the center position.

NOTE:@

The self-canceling system only oper-ates when the motorcycle is moving, sothat the turn signal lights will not self-cancel while you are stopped at anintersection.@

EAU00129

Horn switch Press this switch to sound the horn.

1. Tripmeter reset knob2. Odometer3. Tripmeter

1. Pass switch 2. Dimmer switch3. Turn signal switch4. Horn switch




3-3

3

EAU00138

Engine stop switchSet this switch to to stop the en-gine in case of an emergency, such aswhen the motorcycle overturns orwhen the throttle cable is stuck.

EAU00134

Light switchSet this switch to to turn on theauxiliary light, meter lighting and tail-light. Set the switch to to turn onthe headlight also.

EAU00143

Start switch Push this switch to crank the enginewith the starter.

EC000005

CAUTION:@

See page 5-1 for starting instruc-tions prior to starting the engine. @

EAU00149

Fuel reserve switch FUEL During normal operation, this switchshould be kept in the ON position. Ifyou run out of fuel while riding, set theswitch to RES, refuel as soon as pos-sible, and then set the switch back toON.

NOTE:@

After switching to RES, approximately2.5 L of fuel remain in the fuel tank. @

EAU00152

Clutch leverThe clutch lever is located at the lefthandlebar grip. To disengage theclutch, pull the lever toward the handle-bar grip. To engage the clutch, releasethe lever. The lever should be pulledrapidly and released slowly for smoothclutch operation.The clutch lever is equipped with aclutch switch, which is part of the ignitioncircuit cut-off system. (See page 3-10for an explanation of the ignition circuitcut-off system.)

1. Engine stop switch 2. Light switch 3. Start switch 4. Fuel reserve switch FUEL

1. Clutch lever




3-4

3

EAU00157

Shift pedalThe shift pedal is located on the leftside of the engine and is used in com-bination with the clutch lever whenshifting the gears of the 5-speed con-stant-mesh transmission equipped onthis motorcycle.

EAU00158

Brake leverThe brake lever is located at the righthandlebar grip. To apply the frontbrake, pull the lever toward the handle-bar grip.

EAU00162

Brake pedalThe brake pedal is on the right side ofthe motorcycle. To apply the rearbrake, press down on the brake pedal.

1. Shift pedal 1. Brake lever 1. Brake pedal




3-5

3

EAU03712

Fuel tank cap

To open the fuel tank capInsert the key into the lock and turn it1/4 turn clockwise. The lock will be re-leased and the fuel tank cap can beopened.

To close the fuel tank cap1. Push the fuel tank cap into posi-

tion with the key inserted in thelock.

2. Turn the key counterclockwise tothe original position, and then re-move it.

NOTE:_

The fuel tank cap cannot be closed un-less the key is in the lock. In addition,the key cannot be removed if the cap isnot properly closed and locked. _

EWA00025

WARNING_

Make sure that the fuel tank cap isproperly closed before riding. _

EAU01183

FuelMake sure that there is sufficient fuel inthe tank. Fill the fuel tank to the bottomof the filler tube as shown in the illustra-tion.

EW000130

WARNING@

l Do not overfill the fuel tank, oth-erwise it may overflow when thefuel warms up and expands.

l Avoid spilling fuel on the hotengine.

@

1. Unlock. 1. Fuel tank filler tube2. Fuel level




3-6

3

EAU00185

CAUTION:@

Immediately wipe off spilled fuelwith a clean, dry, soft cloth, sincefuel may deteriorate painted surfac-es or plastic parts. @

EAU00191

NOTE:@

If knocking (or pinging) occurs, usegasoline of a different brand or with ahigher octane grade. @

EAU02976

Starter (choke) leverStarting a cold engine requires a richerair-fuel mixture, which is supplied bythe starter (choke).Move the lever in direction a to turn onthe starter (choke).Move the lever in direction b to turn offthe starter (choke).

Recommended fuel:Regular unleaded gasoline with a research octane number of 91 or higher

Fuel tank capacity:Total amount:

13.5 LReserve amount:

2.5 L

1. Starter (choke) lever




3-7

3

EAU02934

Steering lock

To lock the steering 1. Turn the handlebar all the way to

right.2. Open the steering lock cover, and

then insert the key.3. Turn the key 1/8 turn counter-

clockwise, push it in while turningthe handlebar slightly to the left,and then turn the key 1/8 turnclockwise.

4. Check that the steering is locked,remove the key, and then closethe lock cover.

To unlock the steering 1. Open the steering lock cover, and

then insert the key. 2. Push the key in, turn it 1/8 turn

counterclockwise so that it movesout, and then release it.

3. Remove the key, and then closethe lock cover.

EAU02940

Seats

Passenger seat To remove the passenger seat

1. Insert the key into the seat lock,and then turn it clockwise.

2. Pull the passenger seat off.

1. Steering lock 1. Seat lock2. Unlock.




3-8

3

To install the passenger seat1. Insert the projection on the rear of

the passenger seat into the seatholder as shown, and then pushthe front of the seat down to lock itin place.

2. Turn the key counterclockwise,and then remove it.

Rider seat To remove the rider seat

1. Remove the passenger seat. 2. Remove the bolts, and then pull

the rider seat off.

To install the rider seat1. Insert the projections on the front

of the rider seat into the seat hold-ers as shown, place the seat in theoriginal position, and then tightenthe bolts.

2. Install the passenger seat.

NOTE:@

Make sure that the seats are properlysecured before riding. @

1. Projection2. Seat holder

1. Bolt ( 2) 1. Seat holder ( 2)2. Projection ( 2)




3-9

3

EAU00260

Helmet holderTo open the helmet holder, insert thekey into the lock, and then turn the keyas shown.To lock the helmet holder, place it inthe original position, and then removethe key.

EW000030

WARNING@

Never ride with a helmet attached tothe helmet holder, since the helmetmay hit objects, causing loss ofcontrol and possibly an accident. @

EAU00300

Adjusting the shock absorber assemblies Each shock absorber assembly isequipped with a spring preload adjust-ing ring.

EC000015

CAUTION:@

Never attempt to turn an adjustingmechanism beyond the maximumor minimum settings. @

EW000040

WARNING@

Always adjust both shock absorberassemblies equally, otherwise poorhandling and loss of stability mayresult. @

Adjust the spring preload as follows.To increase the spring preload andthereby harden the suspension, turnthe adjusting ring on each shock ab-sorber assembly in direction a. To de-crease the spring preload and therebysoften the suspension, turn the adjust-ing ring on each shock absorber as-sembly in direction b.

NOTE:@

Align the appropriate notch in the ad-justing ring with the position indicatoron the shock absorber. @

CI-01E

1. Unlock. 1. Spring preload adjusting ring2. Position indicator

Minimum (soft) Standard Maximum (hard)

Setting 1 2 3 4 5




3-10

3

EAU00330

SidestandThe sidestand is located on the left sideof the frame. Raise the sidestand orlower it with your foot while holding themotorcycle upright.

NOTE:@

The built-in sidestand switch is part ofthe ignition circuit cut-off system, whichcuts the ignition in certain situations.(See further down for an explanation ofthe ignition circuit cut-off system.) @

EW000044

WARNING@

The motorcycle must not be riddenwith the sidestand down, or if thesidestand cannot be properlymoved up (or does not stay up), oth-erwise the sidestand could contactthe ground and distract the opera-tor, resulting in a possible loss ofcontrol. Yamahas ignition circuitcut-off system has been designed toassist the operator in fulfilling theresponsibility of raising the side-stand before starting off. Therefore,check this system regularly as de-scribed below and have a Yamahadealer repair it if it does not functionproperly. @

EAU03720

Ignition circuit cut-off system The ignition circuit cut-off system (com-prising the sidestand switch, clutchswitch and neutral switch) has the fol-lowing functions.

l It prevents starting when the trans-mission is in gear and the side-stand is up, but the clutch lever isnot pulled.

l It prevents starting when the trans-mission is in gear and the clutchlever is pulled, but the sidestand isstill down.

l It cuts the running engine whenthe transmission is in gear and thesidestand is moved down.

Periodically check the operation of theignition circuit cut-off system accordingto the following procedure.

EW000045

WARNING_

If a malfunction is noted, have aYamaha dealer check the systembefore riding. _




3-11

3

CD-01E

With the engine turned off:1. Move the sidestand down.2. Make sure that the engine stop switch is set to .3. Turn the key to ON. 4. Shift the transmission into the neutral position.5. Push the start switch.Does the engine start?

The neutral switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

With the engine still running:6. Move the sidestand up.7. Keep the clutch lever pulled.8. Shift the transmission into gear.9. Move the sidestand down.Does the engine stall?

After the engine has stalled:10. Move the sidestand up.11. Keep the clutch lever pulled.12. Push the start switch.Does the engine start?

The sidestand switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

The clutch switch may be defective.The motorcycle should not be ridden until checked by a Yamaha dealer.

NO

NOTE:This check is most reliable if performed witha warmed-up engine.

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO



PRE-OPERATION CHECKS

4

Pre-operation check list...................................................................... 4-1



4-1

4

EAU011144-PRE-OPERATION CHECKSThe condition of a vehicle is the owners responsibility. Vital components can start to deteriorate quickly and unexpectedly,even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or lossof tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-tion, to check the following points before each ride.

EAU03439

Pre-operation check listCO-01E

ITEM CHECKS PAGE

Fuel Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage.

3-53-6

Engine oil Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage.

6-7

Final gear oil Check vehicle for oil leakage. 6-96-10

Front brake

Check operation. If soft or spongy, have Yamaha dealer bleed hydraulic system. Check lever free play. Adjust if necessary. Check fluid level in reservoir. If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage.

6-19, 6-216-23

Rear brake Check operation. Check pedal free play. Adjust if necessary.

6-196-23

Clutch Check operation. Lubricate cable if necessary. Check lever free play. Adjust if necessary.

6-18

Throttle grip Make sure that operation is smooth. Lubricate throttle grip, housing and cables if necessary. Check free play. If necessary, have Yamaha dealer make adjustment.

6-14, 6-24



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 veryshort 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 operatingthe 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.

6-156-17

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. 6-256-26

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. 6-296-30

ITEM CHECKS PAGE



OPERATION AND IMPORTANT RIDING POINTS

5

Starting a cold engine ....................................................................... 5-1Starting a warm engine ...................................................................... 5-2Shifting .............................................................................................. 5-3Recommended shift points (for Switzerland only) .............................. 5-3Tips for reducing fuel consumption .................................................... 5-4Engine break-in ................................................................................. 5-4Parking ............................................................................................... 5-5



5-1

5

EAU003725-OPERATION AND IMPORTANT RIDING POINTS

EAU00373

WARNING@

l Become thoroughly familiarwith all operating controls andtheir functions before riding.Consult a Yamaha dealer re-garding any control or functionthat you do not thoroughly un-derstand.

l Never start the engine or oper-ate it in a closed area for anylength of time. Exhaust fumesare poisonous, and inhalingthem can cause loss of con-sciousness and death within ashort time. Always make surethat there is adequate ventila-tion.

l Before starting out, make surethat the sidestand is up. If thesidestand is not raised com-pletely, it could contact theground and distract the opera-tor, resulting in a possible lossof control.

@

EAU02997*

Starting a cold engine In order for the ignition circuit cut-offsystem to enable starting, one of thefollowing conditions must be met:

l The transmission is in the neutralposition.

l The transmission is in gear withthe clutch lever pulled and thesidestand up.

EW000054

WARNING@

l Before starting the engine,check the function of the igni-tion circuit cut-off system ac-cording to the proceduredescribed on page 3-11.

l Never ride with the sidestanddown.

@

1. Turn the key to ON and makesure that the engine stop switch isset to .

2. Shift the transmission into the neu-tral position.

NOTE:@

When the transmission is in the neutralposition, the neutral indicator lightshould be on, otherwise have aYamaha dealer check the electricalcircuit. @

3. Turn the starter (choke) on andcompletely close the throttle. (Seepage 3-6 for starter (choke) opera-tion.)

4. Start the engine by pushing thestart switch.

NOTE:@

If the engine fails to start, release thestart switch, wait a few seconds, andthen try again. Each starting attemptshould be as short as possible to pre-serve the battery. Do not crank the en-gine more than 10 seconds on any oneattempt. @




5-2

5

5. After starting the engine, move thestarter (choke) lever back halfway.

ECA00045

CAUTION:@

For maximum engine life, never ac-celerate hard when the engine iscold! @

6. When the engine is warm, turn thestarter (choke) off.

NOTE:@

The engine is warm when it respondsnormally to the throttle with the starter(choke) turned off. @

EAU01258

Starting a warm engineFollow the same procedure as for start-ing a cold engine with the exceptionthat the starter (choke) is not requiredwhen the engine is warm.




5-3

5EAU00423

Shifting Shifting gears lets you control theamount of engine power available forstarting off, accelerating, climbing hills,etc.The gear positions are shown in theillustration.

NOTE:@

To shift the transmission into the neu-tral position, press the shift pedal downrepeatedly until it reaches the end of itstravel, and then slightly raise it. @

EC000048

CAUTION:@

l Even with the transmission inthe neutral position, do notcoast for long periods of timewith the engine off, and do nottow the motorcycle for long dis-tances. The transmission isproperly lubricated only whenthe engine is running. Inade-quate lubrication may damagethe transmission.

l Always use the clutch whilechanging gears to avoid dam-aging the engine, transmission,and drive train, which are notdesigned to withstand theshock of forced shifting.

@

EAU02941

Recommended shift points (for Switzerland only)The recommended shift points duringacceleration are shown in the tablebelow.CF-01E

NOTE:@

When shifting down two gears at atime, reduce the speed accordingly(e.g., down to 35 km/h when shiftingfrom 4th to 2nd gear). @

1. Shift pedalN. Neutral position

Shift point(km/h)

1st fi 2nd2nd fi 3rd3rd fi 4th4th fi 5th

23365060




5-4

5

EAU00424

Tips for reducing fuel consumptionFuel consumption depends largely onyour riding style. Consider the followingtips to reduce fuel consumption:

l Thoroughly warm up the engine.l Turn the starter (choke) off as

soon as possible.l Shift up swiftly, and avoid high en-

gine speeds during acceleration.l Do not rev the engine while shift-

ing down, and avoid high enginespeeds with no load on the engine.

l Turn the engine off instead of let-ting it idle for an extended lengthof time (e.g., in traffic jams, at traf-fic lights or at railroad crossings).

EAU00436

Engine break-in There is never a more important periodin the life of your engine than the periodbetween 0 and 1,000 km. For this rea-son, you should read the following ma-terial carefully.Since the engine is brand new, do notput an excessive load on it for the first1,000 km. The various parts in the en-gine wear and polish themselves to thecorrect operating clearances. Duringthis period, prolonged full-throttle oper-ation or any condition that might resultin engine overheating must be avoided.

EAU00444*

0150 kml Avoid prolonged operation above

1/3 throttle. l After every hour of operation, stop

the engine, and then let it cool forfive to ten minutes.

l Vary the engine speed from timeto time. Do not operate the engineat one set throttle position.

150500 kml Avoid prolonged operation above

1/2 throttle. l Rev the engine freely through the

gears, but do not use full throttle atany time.

5001,000 kmAvoid prolonged operation above3/4 throttle.

EC000056*

CAUTION:@

After 1,000 km of operation, the en-gine oil and final gear oil must bechanged, and the oil filter elementreplaced. @




5-5

5

1,000 km and beyondAvoid prolonged full-throttle operation.Vary the speed occasionally.

EC000049

CAUTION:@

If any engine trouble should occurduring the engine break-in period,immediately have a Yamaha dealercheck the vehicle. @

EAU00460

ParkingWhen parking, stop the engine, andthen remove the key from the mainswitch.

EW000058

WARNING@

l Since the engine and exhaustsystem can become very hot,park in a place where pedestri-ans or children are not likely totouch them.

l Do not park on a slope or onsoft ground, otherwise themotorcycle may overturn.

@



6PERIODIC MAINTENANCE AND MINOR REPAIR

Owners tool kit ....................................................6-1Periodic maintenance and lubrication chart .........6-2Checking the spark plugs ....................................6-5Engine oil and oil filter element ............................6-7Final gear oil ........................................................6-9Cleaning the air filter element ............................6-11Adjusting the carburetors....................................6-13Adjusting the engine idling speed.......................6-13Adjusting the throttle cable free play...................6-14Adjusting the valve clearance .............................6-14Tires ...................................................................6-15Spoke wheels .....................................................6-17Adjusting the clutch lever free play ....................6-18Adjusting the brake lever free play......................6-19Adjusting the brake pedal position and

free play ...........................................................6-19Adjusting the rear brake light switch ...................6-21Checking the front brake pads and rear

brake shoes .....................................................6-21Checking the brake fluid level ............................6-22Changing the brake fluid.....................................6-23

Checking and lubricating the cables .................. 6-23Checking and lubricating the throttle

grip and cable .................................................. 6-24Checking and lubricating the brake and

shift pedals ...................................................... 6-25Checking and lubricating the brake and

clutch levers ..................................................... 6-25Checking and lubricating the sidestand ............. 6-25Lubricating the rear suspension ........................ 6-26Checking the front fork ....................................... 6-27Checking the steering ........................................ 6-27Checking the wheel bearings............................. 6-28Battery ............................................................... 6-29Replacing the fuses .......................................... 6-31Replacing the headlight bulb.............................. 6-31Replacing a turn signal light bulb or the

tail/brake light bulb ........................................... 6-33Supporting the motorcycle ................................ 6-33Front wheel ....................................................... 6-34Rear wheel ........................................................ 6-35Troubleshooting.................................................. 6-37Troubleshooting chart ........................................ 6-38



6-1

6

EAU004626-PERIODIC MAINTENANCE AND MINOR REPAIR

EAU00464

Safety is an obligation of the owner.Periodic inspection, adjustment and lu-brication will keep your vehicle in thesafest and most efficient condition pos-sible. The most important points of in-spection, adjustment, and lubricationare explained on the following pages.The intervals given in the periodicmaintenance and lubrication chartshould be simply considered as a gen-eral guide under normal riding condi-tions. However, DEPENDING ON THEWEATHER, TERRAIN, GEOGRAPHI-CAL LOCATION, AND INDIVIDUALUSE, THE MAINTENANCE INTER-VALS MAY NEED TO BE SHORT-ENED.

EW000060

WARNING@

If you are not familiar with motor-cycle maintenance work, have aYamaha dealer do it for you. @

EAU03713

Owners tool kit The tool kit is located under the pas-senger seat. (See page 3-7 for passen-ger seat removal procedures.)The service information included in thismanual and the tools provided in theowners tool kit are intended to assistyou in the performance of preventivemaintenance and minor repairs. How-ever, additional tools such as a torquewrench may be necessary to performcertain maintenance work correctly.

NOTE:_

If you do not have the tools or experi-ence required for a particular job, havea Yamaha dealer perform it for you. _

EW000063

WARNING_

Modifications not approved byYamaha may cause loss of perfor-mance and render the vehicle un-safe for use. Consult a Yamahadealer before attempting any chang-es. _

1. Owners tool kit



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-03E

NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL

CHECK1 10 20 30 401 * Fuel line Check fuel hoses and vacuum hose for cracks or damage. 2 * Fuel filter Check condition.

3 Spark plugs Check condition. Clean and regap.

Replace.

4 * Valves Check valve clearance. Adjust.

5 Air filter element Clean. Replace.

6 * Battery Check electrolyte level and specific gravity. Make sure that the breather hose is properly routed.

7 Clutch Check operation. Adjust.

8 * Front brake Check operation, fluid level and vehicle for fluid leakage.

(See NOTE on page 6-4.) Replace brake pads. Whenever worn to the limit

9 * Rear brake Check operation and adjust brake pedal freeplay. Replace brake shoes. Whenever worn to the limit




6-3

6

10 * Brake hose Check for cracks or damage. Replace. (See NOTE on page 6-4.) Every 4 years

11 * Wheels Check runout, spoke tightness and for damage. Tighten spokes if necessary.

12 * Tires Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

13 * Wheel bearings Check bearing for looseness or damage.

14 * Swingarm Check operation and for excessive play. Lubricate with molybdenum disulfide grease. Every 50,000 km

15 * Steering bearings Check bearing play and steering for roughness. Lubricate with lithium-soap-based grease. Every 20,000 km

16 * Chassis fasteners Make sure that all nuts, bolts and screws are properly tightened.

17 Sidestand Check operation. Lubricate.

18 * Sidestand switch Check operation. 19 * Front fork Check operation and for oil leakage.

20 *Rear shock absorber assemblies Check operation and shock absorbers for oil leakage.

21 * Carburetors Check starter (choke) operation. Adjust engine idling speed and synchronization.

22 Engine oil Change. 23 Engine oil filter element Replace.


CHECK1 10 20 30 40




6-4

6

EAU03541

NOTE:@

l The air filter needs more frequent service if you are riding in unusually wet or dusty areas.l Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

@

24 Final gear oil Check oil level and vehicle for oil leakage. Change.

25 *Front and rear brake switches Check operation.

26 Moving parts and cables Lubricate.

27 *Lights, signals and switches

Check operation. Adjust headlight beam.


CHECK1 10 20 30 40




6-5

6

EAU01486

Checking the spark plugs The spark plugs are important enginecomponents, which are easy to check.Since heat and deposits will cause anyspark plug to slowly erode, the sparkplugs should be removed and checkedin accordance with the periodic mainte-nance and lubrication chart. In addition,the condition of the spark plugs can re-veal the condition of the engine.

To remove a spark plug1. Remove the appropriate spark

plug cover (rear right or front left)by removing the screws.

2. Remove the spark plug cap.

3. Remove the spark plug as shown,with the spark plug wrench includ-ed in the owners tool kit.

To check the spark plugs1. Check that the porcelain insulator

around the center electrode oneach spark plug is a medium-to-light tan (the ideal color when themotorcycle is ridden normally).

2. Check that all spark plugs installedin the engine have the same color.

NOTE:@

If any spark plug shows a distinctly dif-ferent color, the engine could be defec-tive. Do not attempt to diagnose suchproblems yourself. Instead, have aYamaha dealer check the motorcycle. @

3. Check each spark plug for elec-trode erosion and excessive car-bon or other deposits, and replaceit if necessary.

1. Spark plug cover2. Screw ( 2)

1. Spark plug wrench

Specified spark plug:BPR6ES (NGK) or W20EPR-U (DENSO)




6-6

6

To install a spark plug1. Measure the spark plug gap with a

wire thickness gauge and, if nec-essary, adjust the gap to specifica-tion.

2. Clean the surface of the sparkplug gasket and its mating sur-face, and then wipe off any grimefrom the spark plug threads.

3. Install the spark plug with thespark plug wrench, and then tight-en it to the specified torque.

NOTE:@

If a torque wrench is not available wheninstalling a spark plug, a good estimateof the correct torque is 1/41/2 turnpast finger tight. However, the sparkplug should be tightened to the speci-fied torque as soon as possible. @

4. Install the spark plug cap.5. Install the spark plug cover by in-

stalling the screws.

a. Spark plug gap

Spark plug gap:0.70.8 mm

Tightening torque:Spark plug:

20 Nm (2.0 mkg)




6-7

6

EAU02942

Engine oil and oil filter element The engine oil level should be checkedbefore each ride. In addition, the oilmust be changed and the oil filter ele-ment replaced at the intervals specifiedin the periodic maintenance and lubri-cation chart.

To check the engine oil level1. Place the motorcycle on a level

surface and hold it in an uprightposition.

NOTE:@

Make sure that the motorcycle is posi-tioned straight up when checking the oillevel. A slight tilt to the side can result ina false reading. @

2. Start the engine, warm it up forseveral minutes, and then turn itoff.

3. Wait a few minutes until the oil set-tles, and then check the oil levelthrough the check window locatedat the bottom-left side of the crank-case.

NOTE:@

The engine oil should be between theminimum and maximum level marks. @

4. If the engine oil is below the mini-mum level mark, add sufficient oilof the recommended type to raiseit to the correct level.

To change the engine oil (with or without oil filter element replacement)

1. Start the engine, warm it up forseveral minutes, and then turn itoff.

2. Place an oil pan under the engineto collect the used oil.

1. Engine oil level check window2. Maximum level mark3. Minimum level mark

1. Engine oil filler cap




6-8

6

3. Remove the engine oil filler capand drain bolt to drain the oil fromthe crankcase.

NOTE:@

Skip steps 46 if the oil filter element isnot being replaced. @

4. Remove the oil filter element coverby removing the bolts.

5. Remove and replace the oil filterelement and O-ring.

6. Install the oil filter element coverby installing the bolts and tighten-ing them to the specified torque.

1. Engine oil drain bolt 1. Oil filter element cover2. Bolt ( 3)

1. O-ring2. Oil filter element

Tightening torque:Oil filter element cover bolt:

10 Nm (1.0 mkg)




6-9

6

NOTE:@

Make sure that the O-ring is properlyseated. @

7. Install the engine oil drain bolt, andthen tighten it to the specifiedtorque.

8. Add the specified amount of therecommended engine oil, andthen install and tighten the oil fillercap.

EC000067

CAUTION:@

If the oil level warning light flickersor remains on, immediately turn theengine off and have a Yamaha deal-er check the vehicle. @

9. Start the engine, and then let it idlefor several minutes while checkingit for oil leakage. If oil is leaking,immediately turn the engine offand check for the cause.

10. Turn the engine off, and thencheck the oil level and correct it ifnecessary.

EAU03714

Final gear oil The final gear case must be checkedfor oil leakage before each ride. If anyleakage is found, have a Yamaha deal-er check and repair the motorcycle. Inaddition, the final gear oil level must bechecked and the oil changed as followsat the intervals specified in the periodicmaintenance 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 onthe tire or wheel.

_

Tightening torque:Engine oil drain bolt:

43 Nm (4.3 mkg)

Recommended engine oil:See page 8-1.

Oil quantity:Without oil filter element replacement:

2.6 LWith oil filter element replacement:

2.8 LTotal amount (dry engine):

3.2 L




6-10

6

To check the final gear oil level1. Place the motorcycle on a level


NOTE:_

l The final gear oil level must bechecked on a cold engine.

l Make sure that the motorcycle ispositioned straight up whenchecking the oil level. A slight tilt tothe side can result in a falsereading.

_

2. Remove the oil filler bolt, and thencheck the oil level in the final gearcase.

NOTE:_

The oil level should be at the brim ofthe filler hole. _

3. If the oil is below the brim of the fill-er hole, add sufficient oil of the rec-ommended type to raise it to thecorrect level.

To change the final gear oil1. Place an oil pan under the final

gear case to collect the used oil.2. Remove the oil filler bolt and drain

bolt to drain the oil from the finalgear case.

3. Install the final gear oil drain bolt,and then tighten it to the specifiedtorque.

4. Add the recommended final gearoil to the brim of the filler hole.

NOTE:_

GL4 is a quality rating. Hypoid gear oilsrated GL5 or GL6 may also be used. _

5. Install and tighten the filler bolt.6. Check the final gear case for oil

leakage. If oil is leaking, check forthe cause.

1. Final gear oil filler bolt2. Correct oil level3. Final gear oil drain bolt

Tightening torque:Final gear oil drain bolt:

23 Nm (2.3 mkg)

Recommended final gear oil:Hypoid gear oil SAE 80 (API GL4)or multi-grade hypoid gear oil SAE 80W-90

Oil quantity:0.19 L




6-11

6

EAU03715

Cleaning the air filter element The air filter element should be cleanedat the intervals specified in the periodicmaintenance and lubrication chart.Clean the air filter element more fre-quently if you are riding in unusuallywet or dusty areas.

1. Remove the seats. (See page 3-7for seat removal and installationprocedures.)

2. Remove the fuel tank bolts.

3. Lift the front of the fuel tank to po-sition it away from the air filtercase. (Do not remove the fueltank!)

EW000071

WARNING_

l Make sure that the fuel tank iswell supported.

l Do not tilt or pull the fuel tanktoo much, otherwise the fuelhoses may come loose, whichcould cause fuel leakage.

_

4. Remove the air filter case coverscrew.

5. Slide the air filter case cover so asto unhook the tab on the rear ofthe cover from the holder on theframe, and then lift the air filtercase cover without removing it.

1. Fuel tank2. Bolt ( 3)

1. Screw 1. Air filter case cover2. Tab3. Holder4. Air filter element




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 dirtout with compressed air as shown.If the air filter element is damaged,replace it.

8. Insert the air filter element into theair filter case.

EC000082

CAUTION:_

l Make sure that the air filter ele-ment is properly seated in theair filter case.

l The engine should never be op-erated without the air filter ele-ment installed, otherwise thepiston(s) and/or cylinder(s) maybecome excessively worn.

_

9. Place the air filter case cover in theoriginal position, and then installthe screw.

10. Install the fuel tank by installing thebolts.

EW000131

WARNING_

Make sure that the fuel hoses andvacuum 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, rubberdampers and spacers are posi-tioned properly. _

11. Install the seats.

1. Air filter element 1. Washer2. Rubber damper 3. Spacer




6-13

6

EAU00630

Adjusting the carburetorsThe carburetors are important parts ofthe engine and require very sophisti-cated adjustment. Therefore, most car-buretor adjustments should be left to aYamaha dealer, who has the neces-sary professional knowledge and expe-rience. The adjustment described inthe following section, however, may beserviced by the owner as part of routinemaintenance.

EC000095

CAUTION:@

The carburetors have been set andextensively tested at the Yamahafactory. Changing these settingswithout sufficient technical knowl-edge may result in poor perfor-mance of or damage to the engine. @

EAU01168

Adjusting the engine idling speedThe engine idling speed must bechecked and, if necessary, adjusted asfollows at the intervals specified in theperiodic maintenance and lubricationchart.

NOTE:@

A diagnostic tachometer is needed tomake this adjustment. @

1. Attach the tachometer to the sparkplug lead.

2. Start the engine and warm it upfor several minutes at 1,0002,000 r/min while occasionally rev-ving it to 4,0005,000 r/min.

NOTE:@

The engine is warm when it quickly re-sponds to the throttle. @

3. Check the engine idling speedand, if necessary, adjust it to spec-ification by turning the throttle stopscrew. To increase the engineidling speed, turn the screw in di-rection a. To decrease the engineidling speed, turn the screw indirection b.

NOTE:@

If the specified idling speed cannot beobtained as described above, have aYamaha dealer make the adjustment. @

1. Throttle stop screw

Engine idling speed:1,1501,250 r/min




6-14

6

EAU00635

Adjusting the throttle cable free playThe throttle cable free play shouldmeasure 35 mm at the throttle grip.Periodically check the throttle cablefree play and, if necessary, have aYamaha dealer adjust it.

EAU00637

Adjusting the valve clearanceThe valve clearance changes with use,resulting in improper air-fuel mixtureand/or engine noise. To prevent thisfrom occurring, the valve clearancemust be adjusted by a Yamaha dealerat the intervals specified in the periodicmaintenance and lubrication chart.

a. Throttle cable free play




6-15

6

EAU03362

Tires To maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified tires.

Tire air pressureThe tire air pressure should bechecked and, if necessary, adjustedbefore each ride.

EW000082

WARNING@

l The tire air pressure must bechecked and adjusted on coldtires (i.e., when the temperatureof the tires equals the ambienttemperature).

l The tire air pressure must beadjusted in accordance with theriding speed and with the totalweight of rider, passenger, car-go, and accessories approvedfor this model.

@

CE-01E

CE-07E

EWA00012

WARNING@

Because loading has an enormousimpact on the handling, braking,performance and safety characteris-tics of your motorcycle, you shouldkeep the following precautions inmind.

l NEVER OVERLOAD THEMOTORCYCLE! Operation ofan overloaded motorcycle mayresult in tire damage, loss ofcontrol, or severe injury. Makesure that the total weight of rid-er, passenger, cargo, and ac-cessories does not exceed thespecified maximum load for thevehicle.

l Do not carry along looselypacked items, which can shiftduring a ride.

l Securely pack the heaviestitems close to the center of themotorcycle and distribute theweight evenly on both sides.

Tire air pressure(measured on cold tires)

Load* Front Rear

Up to 90 kg200 kPa2.00 kg/cm22.00 bar

225 kPa2.25 kg/cm22.25 bar

90 kgmaximum200 kPa2.00 kg/cm22.00 bar

250 kPa2.50 kg/cm22.50 bar

Maximum load* 220 kg (except for A)218 kg (for A)* Total weight of rider, passenger, cargo and

accessories




6-16

6

l Adjust the suspension and tireair pressure with regard to theload.

l Check the tire condition and airpressure before each ride.

@

Tire inspectionThe tires must be checked before eachride. If the center tread depth reachesthe specified limit, if the tire has a nailor glass fragments in it, or if the side-wall is cracked, have a Yamaha dealerreplace the tire immediately.CE-08E

NOTE:@

The tire tread depth limits may differfrom country to country. Always complywith the local regulations. @

EW000079

WARNING@

l Have a Yamaha dealer replaceexcessively worn tires. Besidesbeing illegal, operating themotorcycle with excessivelyworn tires decreases riding sta-bility and can lead to loss ofcontrol.

l The replacement of all wheel-and brake-related parts, includ-ing the tires, should be left to aYamaha dealer, who has thenecessary professional knowl-edge and experience.

@

1. Sidewalla. Tire tread depth

Minimum tire tread depth (front and rear) 1.6 mm




6-17

6

Tire informationThis motorcycle is equipped with tubetires.

EW000078

WARNING@

l The front and rear tires shouldbe of the same make and de-sign, otherwise the handlingcharacteristics of the motor-cycle cannot be guaranteed.

l After extensive tests, only thetires listed below have been ap-proved for this model byYamaha Motor Co., Ltd.

@

CE-10E

EAU00681

WARNING@

l Have a Yamaha dealer replaceexcessively worn tires. Besidesbeing illegal, operating themotorcycle with excessivelyworn tires decreases riding sta-bility and can lead to loss ofcontrol.

l The replacement of all wheel-and brake-related parts, includ-ing the tires, should be left to aYamaha dealer, who has thenecessary professional knowl-edge and experience.

l It is not recommended to patcha punctured tube. If unavoid-able, however, patch the tubevery carefully and replace it assoon as possible with a high-quality product.

@

EAU00685

Spoke wheelsTo maximize the performance, durabil-ity, and safe operation of your motor-cycle, note the following pointsregarding the specified wheels.

l The wheel rims should be checkedfor cracks, bends or warpage, andthe spokes for looseness or dam-age before each ride. If any dam-age is found, have a Yamahadealer replace the wheel. Do notattempt even the smallest repair tothe wheel. A deformed or crackedwheel must be replaced.

l The wheel should be balancedwhenever either the tire or wheelhas been changed or replaced. Anunbalanced wheel can result inpoor performance, adverse han-dling characteristics, and a short-ened tire life.

l Ride at moderate speeds afterchanging a tire since the tire sur-face must first be broken in for itto develop its optimal characteris-tics.

FRONTManufacturer Size ModelBridgestone 3.00-19 49S L303ADunlop 3.00-19 49S F14G

REARManufacturer Size ModelBridgestone 140/90-15 M/C 70S G508Dunlop 140/90-15 M/C 70S K425




6-18

6

EAU00694

Adjusting the clutch lever free play The clutch lever free play should mea-sure 1015 mm as shown. Periodicallycheck the clutch lever free play and, ifnecessary, adjust it as follows.

1. Loosen the locknut at the clutchlever.

2. To increase the clutch lever freeplay, turn the adjusting bolt in di-rection a. To decrease the clutchlever free play, turn the adjustingbolt in direction b.

3. If the specified clutch lever freeplay could be obtained as de-scribed above, tighten the locknutand skip the rest of the procedure,otherwise proceed as follows.

4. Fully turn the adjusting bolt at theclutch lever in direction a to loos-en the clutch cable.

5. Loosen the locknut at the crank-case.

6. To increase the clutch lever freeplay, turn the adjusting nut in di-rection a. To decrease the clutchlever free play, turn the adjustingnut in direction b.

7. Tighten the locknut at the clutchlever and the crankcase.

1. Locknut2. Clutch lever free play adjusting boltc. Clutch lever free play

1. Locknut2. Clutch lever free play adjusting nut




6-19

6

EAU00696

Adjusting the brake lever free playThe brake lever free play should mea-sure 25 mm as shown. Periodicallycheck the brake lever free play and, ifnecessary, adjust it as follows.

1. Loosen the locknut at the brakelever.

2. To increase the brake lever freeplay, turn the adjusting bolt in di-rection a. To decrease the brakelever free play, turn the adjustingbolt in direction b.

3. Tighten the locknut.EW000099

WARNING@

l After adjusting the brake leverfree play, check the free playand make sure that the brake isworking properly.

l A soft or spongy feeling in thebrake lever can indicate thepresence of air in the hydraulicsystem. If there is air in the hy-draulic system, have a Yamahadealer bleed the system beforeoperating the motorcycle. Air inthe hydraulic system will dimin-ish the braking performance,which may result in loss of con-trol and an accident.

@

EAU00711

Adjusting the brake pedal position and free play

EW000104

WARNING@

It is advisable to have a Yamahadealer make these adjustments. @

NOTE:@

The brake pedal position should be ad-justed before adjusting the brake pedalfree play. @

1. Brake lever free play adjusting bolt2. Locknutc. Brake lever free play




6-20

6

Brake pedal positionThe brake pedal should be positionedapproximately 38 mm above the top ofthe footrest as shown. Periodicallycheck the brake pedal position and, ifnecessary, adjust it as follows.

1. Loosen the locknut at the brakepedal.

2. To raise the brake pedal, turn theadjusting bolt in direction a. Tolower the brake pedal, turn the ad-justing bolt in direction b.

3. Tighten the locknut.EW000105

WARNING@

After adjusting the brake pedalheight, the brake pedal free playmust be adjusted. @

Brake pedal free playThe brake pedal free play should mea-sure 2030 mm at the brake pedal end.Periodically check the brake pedal freeplay and, if necessary, adjust it asfollows.To increase the brake pedal free play,turn the adjusting nut at the brake rodin direction a. To decrease the brakepedal free play, turn the adjusting nut indirection b.

1. Footrest2. Distance between brake pedal and footresta. Brake pedal free play

1. Brake pedal position adjusting bolt2. Locknut

1. Brake pedal free play adjusting nut




6-21

6

EAU00713

Adjusting the rear brake light switchThe rear brake light switch, which is ac-tivated by the brake pedal, is properlyadjusted when the brake light comeson just before braking takes effect. Ifnecessary, adjust the brake light switchas follows.Turn the adjusting nut while holding therear brake light switch in place. Tomake the brake light come on earlier,turn the adjusting nut in direction a. Tomake 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 rearbrake shoes must be checked for wearat the intervals specified in the periodicmaintenance and lubrication chart.

EAU01119

Front brake padsEach front brake pad is provided withwear indicator grooves, which allowyou to check the brake pad wear with-out having to disassemble the brake.To check the brake pad wear, checkthe wear indicator grooves. If a brakepad has worn to the point that the wearindicators have almost disappeared,have a Yamaha dealer replace thebrake pads as a set.

1. Rear brake light switch2. Rear brake light switch adjusting nut

1. Front brake pad wear indicator groove ( 2)

Front




6-22

6

EAU00727

Rear brake shoesThe rear brake is provided with a wearindicator, which allows you to check thebrake shoe wear without having to dis-assemble the brake. To check thebrake shoe wear, check the position ofthe wear indicator while applying thebrake. If a brake shoe has worn to thepoint that the wear indicator reachesthe wear limit line, have a Yamahadealer replace the brake shoes as aset.

EAU00732

Checking the brake fluid level Insufficient brake fluid may allow air toenter the brake system, possibly caus-ing it to become ineffective.Before riding, check that the brake fluidis above the minimum level mark andreplenish if necessary. A low brake flu-id level may indicate worn brake padsand/or brake system leakage. If thebrake level is low, be sure to check thebrake 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 thehandlebars.

l Use only the recommended quali-ty brake fluid, otherwise the rubberseals may deteriorate, causingleakage and poor braking perfor-mance.

NOTE:@

If DOT 4 is not available, DOT 3 can beused. @

l Refill with the same type of brakefluid. Mixing fluids may result in aharmful chemical reaction andlead to poor braking performance.

l Be careful that water does not en-ter the master cylinder when refill-ing. Water will significantly lowerthe boiling point of the fluid andmay result in vapor lock.

1. Rear brake shoe wear limit2. Rear brake shoe wear indicator

Rear

1. Minimum level mark

Recommended brake fluid: DOT 4




6-23

6

l Brake fluid may deteriorate paint-ed surfaces or plastic parts. Al-ways clean up spilled fluidimmediately.

l As the brake pads wear, it is nor-mal for the brake fluid level togradually go down. However, if thebrake fluid level goes down sud-denly, have a Yamaha dealercheck the cause.

EAU03238

Changing the brake fluidHave a Yamaha dealer change thebrake fluid at the intervals specified inthe periodic maintenance and lubrica-tion chart. In addition, have the oil sealsof the brake master cylinder and caliperas well as the brake hose replaced atthe intervals listed below or whenever itis damaged or leaking.

l Oil seals: Replace every twoyears.

l Brake hose: Replace every fouryears.

EAU02962

Checking and lubricating the cablesThe operation of all control cables andthe condition of the cables should bechecked before each ride, and the ca-bles and cable ends should be lubricat-ed if necessary. If a cable is damagedor does not move smoothly, have aYamaha dealer check or replace it.

EW000112

WARNING@

Damage to the outer sheath may in-terfere with proper cable operationand will cause the inner cable torust. Replace a damaged cable assoon as possible to prevent unsafeconditions. @

Recommended lubricant:Engine oil




6-24

6

EAU03209

Checking and lubricating the throttle grip and cableThe operation of the throttle grip andthe condition of the throttle cableshould be checked before each ride,and the cable should be lubricated orreplaced if necessary.

NOTE:@

Since the throttle grip must be removedto access the throttle cable end, thethrottle grip and the cable should al-ways be lubricated at the same time. @

1. Remove the throttle grip by remov-ing the screws.

2. Disconnect the throttle cable, holdit up, and then apply several dropsof oil to the cable end, allowing it totrickle into the sheath.

3. Connect the throttle cable, andthen grease the inside of the throt-tle grip housing.

4. Grease the metal-to-metal contactsurface of the throttle grip, andthen install the grip by installingthe screws.

Recommended lubricant:Throttle cable:

Engine oilThrottle grip housing and grip:

Lithium-soap-based grease (all-purpose grease)




6-25

6

EAU03370

Checking and lubricating the brake and shift pedals The operation of the brake and shiftpedals should be checked before eachride, and the pedal pivots should be lu-bricated if necessary.

EAU03164

Checking and lubricating the brake and clutch leversThe operation of the brake and clutchlevers should be checked before eachride, and the lever pivots should be lu-bricated if necessary.

EAU03165

Checking and lubricating the sidestandThe operation of the sidestand shouldbe checked before each ride, and thesidestand pivot and metal-to-metalcontact surfaces should be lubricated ifnecessary.

EW000113

WARNING@

If the sidestand does not move upand down smoothly, have a Yamahadealer check or repair it. @

Recommended lubricant:Lithium-soap-based grease (all-purpose grease)





6-26

6

EAU00790

Lubricating the rear suspension The pivoting points of the rear suspen-sion must be lubricated at the intervalsspecified in the periodic maintenanceand lubrication chart.


Recommended lubricant:Molybdenum disulfide grease




6-27

6

EAU02939

Checking the front forkThe condition and operation of the frontfork must be checked as follows at theintervals specified in the periodic main-tenance and lubrication chart.

To check the conditionEW000115

WARNING@

Securely support the motorcycle sothat there is no danger of it fallingover. @

Check the inner tubes for scratches,damage and excessive oil leakage.

To check the operation1. Place the motorcycle on a level


2. While applying the front brake,push down hard on the handle-bars several times to check if thefront fork compresses and re-bounds smoothly.

EC000098

CAUTION:@

If any damage is found or the frontfork does not operate smoothly,have a Yamaha dealer check or re-pair it. @

EAU00794

Checking the steeringWorn or loose steering bearings maycause danger. Therefore, the operationof the steering must be checked as fol-lows at the intervals specified in the pe-riodic maintenance and lubricationchart.

1. Place a stand under the engine toraise the front wheel off theground.

EW000115

WARNING@

Securely support the motorcycle sothat there is no danger of it fallingover. @




6-28

6

2. Hold the lower ends of the frontfork legs and try to move them for-ward and backward. If any freeplay can be felt, have a Yamahadealer check or repair thesteering.

EAU01144

Checking the wheel bearingsThe front and rear wheel bearings mustbe checked at the intervals specified inthe periodic maintenance and lubrica-tion chart. If there is play in the wheelhub or if the wheel does not turnsmoothly, have a Yamaha dealercheck the wheel bearings.




6-29

6 EAU00798Battery A poorly maintained battery will cor-rode and discharge quickly. The elec-trolyte level, battery lead connectionsand breather hose routing should bechecked before each ride and at the in-tervals specified in the periodic mainte-nance and lubrication chart.

To check the electrolyte level1. Place the motorcycle on a level


NOTE:@

Make sure that the motorcycle is posi-tioned straight up when checking theelectrolyte level. @

2. Check the electrolyte level in thebattery.

NOTE:@

The electrolyte should be between theminimum and maximum level marks. @

3. If the electrolyte is at or below theminimum level mark, add distilledwater to raise it to the maximumlevel mark.

EW000116

WARNING@

l Electrolyte is poisonous anddangerous since it contains sul-furic acid, which causes severeburns. Avoid any contact withskin, eyes or clothing and al-ways shield your eyes whenworking near batteries. In caseof contact, administer the fol-lowing FIRST AID. EXTERNAL: Flush with plenty

of water. INTERNAL: Drink large quan-

tities of water or milk and im-mediately call a physician.

EYES: Flush with water for15 minutes and seek promptmedical attention.

l Batteries produce explosive hy-drogen gas. Therefore, keepsparks, flames, cigarettes, etc.,

1. Battery2. Pass through the battery case.3. Pass through the frame.4. Pass through the guide.5. Pass through the engine bracket.6. Battery breather hose

1. Maximum level mark2. Minimum level mark




6-30

6

away from the battery and pro-vide sufficient ventilation whencharging it in an enclosedspace.

l KEEP THIS AND ALL BATTER-IES OUT OF THE REACH OFCHILDREN.

@

EC000100

CAUTION:@

Use only distilled water, as tap watercontains minerals that are harmfulto the battery. @

4. Check and, if necessary, tightenthe battery lead connections andcorrect the breather hose routing.

To store the battery1. If the motorcycle will not be used

for more than one month, removethe battery, fully charge it, andthen place it in a cool, dry place.

2. If the battery will be stored formore than two months, check thespecific gravity of the electrolyte atleast once a month and fullycharge the battery whenevernecessary.

3. Fully charge the battery beforeinstallation.

4. After installation, make sure thatthe battery leads are properly con-nected to the battery terminals andthat the breather hose is properlyrouted, in good condition, and notobstructed.

EC000099

CAUTION:@

If the breather hose is positioned insuch a way that the frame is ex-posed to electrolyte or gas expelledfrom the battery, the frame couldsuffer structural and externaldamages. @




6-31

6EAU00818

Replacing the fuses The fuse box is located under the riderseat. (See page 3-8 for rider seat re-moval and installation procedures.)If a fuse is blown, replace it as follows.

1. Turn the key to OFF and turn offthe electrical circuit in question.

2. Remove the blown fuse, and theninstall a new fuse of the specifiedamperage.

EC000103

CAUTION:@

Do not use a fuse of a higher amper-age rating than recommended toavoid causing extensive damage tothe electrical system and possibly afire. @

3. Turn the key to ON and turn onthe electrical circuit in question tocheck if the device operates.

4. If the fuse immediately blowsagain, have a Yamaha dealercheck the electrical system.

EAU03003

Replacing the headlight bulbThis motorcycle is equipped with aquartz bulb headlight. If the headlightbulb burns out, replace it as follows.

1. Remove the headlight unit by re-moving the screws.

1. Main fuse2. Headlight fuse3. Signaling system fuse4. Ignition fuse5. Spare fuse ( 2)

Specified fuses:Main fuse: 30 AHeadlight fuse: 15 ASignaling system fuse: 15 AIgnition fuse: 15 A

1. Screw ( 2)




6-32

6

2. Disconnect the headlight coupler,and then remove the headlight unitand bulb cover.

3. Remove the headlight bulb holderby turning it counterclockwise, andthen remove the defective bulb.

EW000119

WARNING@

Headlight bulbs get very hot. There-fore, keep flammable products awayfrom a lit headlight bulb, and do nottouch the bulb until it has cooleddown. @

4. Place a new bulb into position, andthen secure it with the bulb holder.

EC000105

CAUTION:@

Do not touch the glass part of theheadlight bulb to keep it free fromoil, otherwise the transparency ofthe glass, the luminosity of the bulb,and the bulb life will be adversely af-fected. Thoroughly clean off any dirtand fingerprints on the headlightbulb using a cloth moistened withalcohol or thinner. @

5. Install the bulb cover, and thenconnect the coupler.

6. Install the headlight unit by install-ing the screws.

7. Have a Yamaha dealer adjust theheadlight beam if necessary.

1. Headlight coupler2. Headlight bulb cover

1. Headlight bulb holder 1. Do not touch this area.




6-33

6

EAU00855

Replacing a turn signal light bulb or the tail/brake light bulb

1. Remove the lens by removing thescrews.

2. Remove the defective bulb bypushing it in and turning it counter-clockwise.

3. Insert a new bulb into the socket,push it in, and then turn it clock-wise until it stops.

4. Install the lens by installing thescrews.

EC000108

CAUTION:@

Do not overtighten the screws, oth-erwise the lens may break. @

EAU01579

Supporting the motorcycle Since this model is not equipped with acenterstand, follow these precautionswhen removing the front and rearwheel or performing other mainte-nance requiring the motorcycle tostand upright. Check that the motor-cycle is in a stable and level positionbefore starting any maintenance. Astrong wooden box can be placed un-der the engine for added stability.

To service the front wheel1. Stabilize the rear of the motorcycle

by using a motorcycle stand or, ifan additional motorcycle stand isnot available, by placing a jack un-der the frame in front of the rearwheel.

2. Raise the front wheel off theground by using a motorcyclestand.

1. Screw ( 2) 1. Tail/brake light bulb ( 2)




6-34

6

To service the rear wheelRaise the rear wheel off the ground byusing a motorcycle stand or, if a motor-cycle stand is not available, by placinga jack either under each side of theframe in front of the rear wheel or undereach side of the swingarm.

EAU03239

Front wheel

To remove the front wheel EW000122

WARNING_

l It is advisable to have a Yamahadealer service the wheel.

l Securely support the motor-cycle so that there is no dangerof it falling over.

_

1. Disconnect the speedometer ca-ble from the front wheel.

2. Loosen the front wheel axle pinchbolt, then the wheel axle.

3. Lift the front wheel off the groundaccording to the procedure onpage 6-33.

4. Pull the wheel axle out, and thenremove the wheel.

ECA00048

CAUTION:_

Do not apply the brake after thewheel has been removed togetherwith the brake disc, otherwise thebrake pads will be forced shut. _

1. Speedometer cable 1. Front wheel axle pinch bolt2. Wheel axle




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 forklegs.

NOTE:_

Make sure that there is enough spacebetween the brake pads before insert-ing the brake disc and that the slot inthe speedometer gear unit fits over theretainer 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 handlebarseveral times to check for properfork operation.

6. Tighten the wheel axle to thespecified torque.

7. Install the front wheel axle pinchbolt, and then tighten it to thespecified torque.

8. Connect the speedometer cable.

EAU01337

Rear wheel

To remove the rear wheel EW000122

WARNING_

l It is advisable to have a Yamahadealer service the wheel.

l Securely support the motor-cycle so that there is no dangerof 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 mkg)

Tightening torque:Front wheel axle pinch bolt:

23 Nm (2.3 mkg)

1. Axle nut cotter pin2. Axle nut




6-36

62. Disconnect the brake torque rodfrom the brake shoe plate by re-moving the cotter pin, the nut, andthe bolt.

3. Lift the rear wheel off the groundaccording to the procedure onpage 6-33.

4. Remove the brake pedal free playadjusting nut, and then disconnectthe brake rod from the brake cam-shaft lever.

5. Remove the axle nut.

6. Loosen the rear wheel axle pinchbolt, and then pull the wheel axleout.

7. Pull the wheel to the right to sepa-rate it from the final gear case, andthen remove it.

1. Rear wheel axle pinch bolt2. Brake pedal free play adjusting nut3. Brake rod4. Brake torque rod bolt/nut/cotter pin5. Brake torque rod6. Wheel axle




6-37

6

EAU01406

To install the rear wheel 1. Apply a light coating of lithium-

soap-based grease to the splinesof the final gear case and wheelhub.

2. Install the wheel by inserting thewheel axle.

3. Install the brake rod onto the brakecamshaft lever, and then installthe brake pedal free play adjustingnut onto the brake rod.

4. Connect the brake torque rod tothe brake shoe plate by installingthe bolt and the nut.

5. Install the rear wheel axle pinchbolt.

6. Lower the rear wheel so that it ison the ground.

7. Tighten the axle nut, pinch boltand brake torque rod nut to thespecified torques.

8. Install the brake torque rod cotterpin.

EW000124

WARNING_

Always use a new cotter pin. _

9. Adjust the brake pedal free play.(See page 6-20 for brake pedalfree play adjustment procedures.)

EW000103

WARNING_

After adjusting the brake pedal freeplay, check the operation of thebrake light. _

EAU01008

TroubleshootingAlthough Yamaha motorcycles receivea thorough inspection before shipmentfrom the factory, trouble may occur dur-ing operation. Any problem in the fuel,compression, or ignition systems, forexample, can cause poor starting andloss of power.The following troubleshooting chartrepresents a quick and easy procedurefor checking these vital systems your-self. However, should your motorcyclerequire any repair, take

xv535 owner's manual

Documents

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yamaha team

book page

operatingthis motorcycle

contactyour yamaha dealer

yamaha world of motorcycling

recycled paper yamaha

important riding points