brake fluid YAMAHA XV535 2001 Owners Manual

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s 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 loss
of 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 list
CO-01E
ITEM CHECKS PAGE
Fuel• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.3-5–3-6
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. 6-9–6-10
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, 6-21–6-23
Rear brake• Check operation.
• Check pedal free play.
• Adjust if necessary.6-19–6-23
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
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PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-24
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-15–6-17
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-25
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-25
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-25–6-26
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.—
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-10
Battery• Check fluid level.
• Fill with distilled water if necessary.6-29–6-30 ITEM CHECKS PAGE
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6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Checking the spark plugs .................................... 6-5
Engine oil and oil filter element ............................ 6-7
Final gear oil ........................................................ 6-9
Cleaning the air filter element ............................ 6-11
Adjusting the carburetors .................................... 6-13
Adjusting the engine idling speed ....................... 6-13
Adjusting the throttle cable free play ................... 6-14
Adjusting the valve clearance ............................. 6-14
Tires ................................................................... 6-15
Spoke wheels ..................................................... 6-17
Adjusting the clutch lever free play .................... 6-18
Adjusting the brake lever free play ...................... 6-19
Adjusting the brake pedal position and
free play ........................................................... 6-19
Adjusting the rear brake light switch ................... 6-21
Checking the front brake pads and rear
brake shoes ..................................................... 6-21
Checking the brake fluid level ............................ 6-22
Changing the brake fluid ..................................... 6-23Checking and lubricating the cables .................. 6-23
Checking and lubricating the throttle
grip and cable .................................................. 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-25
Checking and lubricating the brake and
clutch levers ..................................................... 6-25
Checking and lubricating the sidestand ............. 6-25
Lubricating the rear suspension ........................ 6-26
Checking the front fork ....................................... 6-27
Checking the steering ........................................ 6-27
Checking the wheel bearings ............................. 6-28
Battery ............................................................... 6-29
Replacing the fuses .......................................... 6-31
Replacing the headlight bulb .............................. 6-31
Replacing a turn signal light bulb or the
tail/brake light bulb ........................................... 6-33
Supporting the motorcycle ................................ 6-33
Front wheel ....................................................... 6-34
Rear wheel ........................................................ 6-35
Troubleshooting .................................................. 6-37
Troubleshooting chart ........................................ 6-38
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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-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.ÖÖÖÖ
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6*Battery• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.ÖÖÖÖ Ö
7Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
8*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Rear brake• Check operation and adjust brake pedal freeplay.ÖÖÖÖÖ Ö
• Replace brake shoes. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
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.ÖÖ Ö
• Change.ÖÖÖ
25
*Front and rear brake
switches• Check operation.ÖÖÖÖÖ Ö
26 Moving parts and cables• Lubricate.ÖÖÖÖ Ö
27*Lights, signals and
switches• Check operation.
• Adjust headlight beam.ÖÖÖÖÖ Ö NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-22
6
EAU00727
Rear brake shoes
The rear brake is provided with a wear
indicator, which allows you to check the
brake shoe wear without having to dis-
assemble the brake. To check the
brake shoe wear, check the position of
the wear indicator while applying the
brake. If a brake shoe has worn to the
point that the wear indicator reaches
the wear limit line, have a Yamaha
dealer replace the brake shoes as a
set.
EAU00732
Checking the brake fluid level Insufficient brake fluid may allow air to
enter the brake system, possibly caus-
ing it to become ineffective.
Before riding, check that the brake fluid
is above the minimum level mark and
replenish if necessary. A low brake flu-
id level may indicate worn brake pads
and/or brake system leakage. If the
brake level is low, be sure to check the
brake 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 the
handlebars.
l
Use only the recommended quali-
ty brake fluid, otherwise the rubber
seals may deteriorate, causing
leakage and poor braking perfor-
mance.
NOTE:@ If DOT 4 is not available, DOT 3 can be
used. @l
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking performance.
l
Be careful that water does not en-
ter the master cylinder when refill-
ing. Water will significantly lower
the boiling point of the fluid and
may result in vapor lock.
1. Rear brake shoe wear limit
2. Rear brake shoe wear indicatorRear
1. Minimum level mark
Recommended brake fluid: DOT 4
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-23
6
l
Brake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
l
As the brake pads wear, it is nor-
mal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down sud-
denly, have a Yamaha dealer
check the cause.
EAU03238
Changing the brake fluidHave a Yamaha dealer change the
brake fluid at the intervals specified in
the periodic maintenance and lubrica-
tion chart. In addition, have the oil seals
of the brake master cylinder and caliper
as well as the brake hose replaced at
the intervals listed below or whenever it
is damaged or leaking.l
Oil seals: Replace every two
years.
l
Brake hose: Replace every four
years.
EAU02962
Checking and lubricating the
cablesThe operation of all control cables and
the condition of the cables should be
checked before each ride, and the ca-
bles and cable ends should be lubricat-
ed if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
EW000112
WARNING
@ Damage to the outer sheath may in-
terfere with proper cable operation
and will cause the inner cable to
rust. Replace a damaged cable as
soon as possible to prevent unsafe
conditions. @
Recommended lubricant:
Engine oil
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SPECIFICATIONS
8-3
8
Maximum load* 220 kg (except for A)
218 kg (for A)
Tire air pressure
(measured on cold tires)
Up to 90 kg*
Front 200 kPa (2.00 kg/cm
2, 2.00 bar)
Rear 225 kPa (2.25 kg/cm2, 2.25 bar)
90 kg–maximum*
Front 200 kPa (2.00 kg/cm2, 2.00 bar)
Rear 250 kPa (2.50 kg/cm2, 2.50 bar)
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
Type Spoke wheel
Size 19 ´ MT 1.85
Rear
Type Spoke wheel
Size 15 M/C ´ MT 3.00
Brakes
Front
Type Single disc brake
Operation Right hand
Fluid DOT 4 or DOT 3Rear
Type Drum brake
Operation Right foot
Suspension
Front Telescopic fork
Rear Swingarm
Springs/shock absorbers
Front Coil spring / oil damper
Rear Coil spring / oil damper
Wheel travel
Front 150 mm
Rear 85 mm
Electrical system
Ignition system T.C.I. (digital)
Charging system
Type A.C. magneto
Standard output 14 V, 24 A @ 5,000 r/min
Battery
Model GM12AZ-3A-2
Voltage, capacity 12 V, 12 Ah
Headlight typeQuartz bulb (halogen)
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10-INDEXAAir filter element, cleaning ...................... 6-11BBattery ................................................... 6-29
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-25
Brake fluid, changing ............................. 6-23
Brake fluid level, checking...................... 6-22
Brake lever...............................................3-4
Brake lever free play, adjusting .............. 6-19
Brake light switch, adjusting ................... 6-21
Brake pads and shoes, checking ........... 6-21
Brake pedal..............................................3-4
Brake pedal position and free play,
adjusting .............................................. 6-19CCables, checking and lubricating............ 6-23
Carburetors, adjusting............................ 6-13
Care.........................................................7-1
Clutch lever ..............................................3-3
Clutch lever free play, adjusting ............. 6-18
Conversion table ......................................8-5DDimmer switch .........................................3-2
EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-7
Engine stop switch................................... 3-3FFinal gear oil ............................................ 6-9
Front fork, checking ............................... 6-27
Fuel ......................................................... 3-5
Fuel consumption, tips for reducing ......... 5-4
Fuel reserve switch.................................. 3-3
Fuel tank cap ........................................... 3-5
Fuses, replacing .................................... 6-31HHandlebar switches ................................. 3-2
Headlight bulb, replacing ....................... 6-31
Helmet holder .......................................... 3-9
High beam indicator light ......................... 3-1
Horn switch ............................................. 3-2IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-13
Ignition circuit cut-off system.................. 3-10
Indicator lights ......................................... 3-1KKey identification number ........................ 9-1
LLight switch ..............................................3-3MMain switch ..............................................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-1PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-2
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seats .......................................................3-7
Passenger seat...................................3-7
Rider seat ...........................................3-8
Shifting .....................................................5-3
Shift pedal ................................................3-4
Shift points (for Switzerland only) .............5-3
Shock absorber assemblies, adjusting .....3-9
Sidestand ...............................................3-10
Sidestand, checking and lubricating .......6-25
E_3bt.book Page 1 Thursday, September 7, 2000 10:01 AM