YAMAHA XV535 2000 Service Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
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11*Tires¥ Check tread depth and for damage.
¥ Replace if necessary.
¥ Check air pressure.
¥ Correct if necessary.ÖÖ
12
*Wheel bearings¥ Check bearing for looseness or damage.
¥ Replace if necessary. ÖÖ
13
*Swingarm¥ Check swingarm pivoting point for play.
¥ Correct if necessary.
¥ Lubricate with molybdenum disulfide grease.ÖÖ
14
*Steering bearings¥ Check bearing play and steering for roughness.
¥ Correct accordingly.
¥ Lubricate with lithium soap base grease every 24,000 km
or 24 months (whichever comes first).ÖÖ
15
*Chassis fasteners¥ Make sure that all nuts, bolts and screws are properly tightened.
¥ Tighten if necessary.ÖÖ
16 Sidestand¥ Check operation.
¥ Lubricate and repair if necessary.ÖÖ
17
*Sidestand switch¥ Check operation.
¥ Replace if necessary.ÖÖÖ
18
*Front fork¥ Check operation and for oil leakage.
¥ Correct accordingly.ÖÖ
19
*Rear shock absorber
assemblies¥ Check operation and shock absorbers for oil leakage.
¥ Replace shock absorber assembly if necessary.ÖÖ
20
*Carburetors¥ Check engine idling speed, synchronization and starter operation.
¥ Adjust if necessary.ÖÖÖ
21 Engine oil¥ Check oil level and vehicle for oil leakage.
¥ Correct if necessary.
¥ Change. (Warm engine before draining.)ÖÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)

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PERIODIC MAINTENANCE AND MINOR REPAIR
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* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer.
EAU02970
NOTE:
lThe air filter needs more frequent service if you are riding in unusually wet or dusty areas.
lHydraulic brake system
¥ When disassembling the master cylinder or caliper, always replace the brake fluid. Check the brake fluid level regularly
and fill as required.
¥ Replace the oil seals on the inner parts of the master cylinder and caliper every two years.
¥ Replace the brake hoses every four years or if cracked or damaged.
22 Engine oil filter element¥ Replace.ÖÖ
23 Final gear oil¥ Check oil level and vehicle for oil leakage.
¥ Change oil at initial 1,000 km and thereafter every 24,000 km
or 24 months (whichever comes first).ÖÖÖ NO. ITEM CHECKS AND MAINTENANCE JOBSINITIAL
(1,000 km)EVERY
6,000 km
or
6 months
(whichever
comes first)12,000 km
or
12 months
(whichever
comes first)

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PERIODIC MAINTENANCE AND MINOR REPAIR
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2 1
1. Cylinder head cover
2. Screw (´ 2)
EAU01486
Spark plugs
Removal
1. Remove the rear right and front
left cylinder head covers by re-
moving the screws.
2. Remove the spark plug caps.
1
1. Spark plug wrench
3. Use the spark plug wrench in the
tool kit to remove the spark plugs
as shown.
Inspection
The spark plug is an important engine
component and is easy to inspect. The
condition of the spark plug can indicate
the condition of the engine. Normally,
all spark plugs from the same engine
should have the same color on the
white insulator around the center elec-
trode. The ideal color at this point is a
medium-to-light tan color for a motor-
cycle that is being ridden normally. If
one spark plug shows a distinctly differ-ent color, there could be something
wrong with the engine. Do not attempt
to diagnose such problems yourself. In-
stead, take the motorcycle to a
Yamaha dealer. You should periodical-
ly remove and inspect the spark plugs
because heat and deposits will cause
any spark plug to slowly break down
and erode. If electrode erosion be-
comes excessive, or if carbon and oth-
er deposits are excessive, you should
replace the spark plug with the speci-
fied plug.
Specified spark plug:
For CH:
BPR7ES (NGK) or
W22EPR-U (DENSO)
Except for CH:
BPR6ES (NGK) or
W20EPR-U (DENSO)

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a. Spark plug gap
Installation
1. Measure the electrode gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the gasket surface. Wipe off
any grime from the threads.
3. Install the spark plug and tighten it
to the specified torque. Spark plug gap:
0.7 ~ 0.8 mm
NOTE:
If a torque wrench is not available when
you are installing a spark plug, a good
estimate of the correct torque is 1/4 to
1/2 turn past finger tight. Have the
spark plug tightened to the specified
torque as soon as possible.
4. Install the spark plug caps, the cyl-
inder head covers and the screws. Tightening torque:
Spark plug:
20 Nm (2.0 mákg)

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1. Oil level window
2. Maximum level mark
3. Minimum level mark
EAU02942
Engine oil
Oil level inspection
1. Place the motorcycle on a level
place and hold it in an upright posi-
tion. Warm up the engine for sev-
eral minutes.
NOTE:
Be sure the motorcycle is positioned
straight up when checking the oil level.
A slight tilt toward the side can result in
false readings.2. With the engine stopped, check
the oil level through the level win-
dow located at the lower part of
the left side crankcase cover.
NOTE:
Wait a few minutes until the oil level
settles before checking.
3. The oil level should be between
the maximum and minimum
marks. If the level is low, fill the en-
gine with sufficient oil to the speci-
fied level.
1. Engine oil filler cap
Engine oil and oil filter element
replacement
1. Warm up the engine for a few min-
utes.
2. Stop the engine. Place an oil pan
under the engine and remove the
oil filler cap.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Engine oil drain bolt
3. Remove the drain bolt and drain
the oil.
1. Oil filter cover
2. Bolt (´ 3)
4. Remove the oil filter bolts, oil filter
and O-ring.
5. Install the drain bolt and tighten it
to the specified torque.
6. Install the new oil filter, new O-ring
and the filter cover. Then tighten the
oil filter bolts to the specified torque. Tightening torque:
Drain bolt:
43 Nm (4.3 mákg)
Tightening torque:
Oil filter bolts:
10 Nm (1.0 mákg)
1. O-ring
2. Oil filter element
NOTE:
Make sure the O-ring is seated proper-
ly.
7. Fill the engine with oil. Install the
oil filler cap and tighten it.
Recommended oil:
See page 8-1.
Oil quantity:
Total amount:
3.2 L
Periodic oil change:
2.6 L
With oil filter replacement:
2.8 L

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EC000066
CAUTION:
lDo not put in any chemical addi-
tives. Engine oil also lubricates
the clutch and additives could
cause clutch slippage.
lBe sure no foreign material en-
ters the crankcase.
8. Start the engine and warm it up for
a few minutes. While warming up,
check for oil leakage. If oil leakage
is found, stop the engine immedi-
ately and check for the cause.
1. Final gear oil drain bolt
2. Final gear oil
3. Final gear oil filler bolt
4. Correct level
EAU02943
Final gear oil
EW000066
Do not let foreign material enter the
final gear case. Be sure oil does not
get on the tire or wheel.
Oil level inspection
1. Place the motorcycle on a level
place and hold it in an upright posi-
tion. The engine should be cool at
ambient temperature.2. Remove the oil filler bolt and
check the oil level. The oil level
should be at the brim of the filler
hole. Add the recommended oil if
necessary.
Oil replacement
1. Place an oil pan under the final
gear case.
2. Remove the oil filler bolt and drain
bolt to drain the oil.
3. Install and tighten the drain bolt to
the specified torque.
4. Fill the gear case to the brim of the
filler hole with the recommended
oil. Tightening torque:
Drain bolt:
23 Nm (2.3 mákg)

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NOTE:
ÒGL-4Ó is a quality and additive rating.
Hypoid gear oils rated ÒGL-5Ó or ÒGL-6Ó
may also be used.
5. Install and tighten the filler bolt to
the specified torque.
6. After replacing the final gear oil, be
sure to check for oil leakage. Final gear case capacity:
0.19 L
Recommended oil:
SAE 80 API GL-4 Hypoid gear oil
If desired, an SAE 80W90 hypoid
gear oil may be used for all
conditions.
Tightening torque:
Oil filler bolt:
23 Nm (2.3 mákg)
1. Fuel tank
2. Bolt (´ 3)
EAU02998
Air filter
The air filter should be cleaned at the
specified intervals. It should be cleaned
more frequently if you are riding in un-
usually wet or dusty areas.
1. Remove the seats. (See page 3-7
for seat removal and installation
procedures.)
2. Remove the fuel tank bolts.
1. Screw
3. Lift the front of the fuel tank up-
ward and position it away from the
air filter. (Do not remove the fuel
tank.)
EW000071
lSupport the fuel tank carefully
during this procedure.
lDo not tilt the fuel tank too
much or pull it too hard be-
cause the fuel hose connec-
tions may become loose
causing fuel leakage.
4. Remove the air filter case cover
screw.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Air filter case cover
2. Tab
3. Holder
4. Air filter
5. Slide the air filter case cover so as
to unhook the tab on the rear of
the cover from the holder on the
frame. Then lift the air filter case
cover upward without removing it.
6. Pull out the air filter element and
tap it lightly to remove most of the
dust and dirt. Blow out the remain-
ing dirt with compressed air as
shown. If the air filter element is
damaged, replace it.7. Reassemble by reversing the re-
moval procedure.
EC000082
CAUTION:
lMake sure the air filter is prop-
erly seated in the air filter case.
lThe engine should never be run
without the air filter installed.
Excessive piston and/or cylin-
der wear may result.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Washer
2. Rubber damper
3. Spacer
EW000131
Make sure that the fuel hoses and
vacuum hose are properly connect-
ed, in place and not pinched. If a
hose is damaged, be sure to replace
it.
EC000086
CAUTION:
When reinstalling the fuel tank hold-
ing bolts, make sure that the wash-
ers, damper rubbers and spacers
are positioned properly.
EAU00630
Carburetor adjustment
The carburetors are important parts of
the engine and require very sophisti-
cated adjustment. Most adjustments
should be left to a Yamaha dealer who
has the professional knowledge and
experience to do so. However, the idle
speed may be adjusted by the owner
as part of routine maintenance.
EC000095
CAUTION:
The carburetors were set at the
Yamaha factory after many tests. If
they are changed, poor engine per-
formance and damage may result.