YAMAHA XV535 2000 Repair Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU02986
Sidestand lubrication
Lubricate the sidestand pivoting point
and metal-to-metal contact surfaces.
Check that the sidestand moves up
and down smoothly.
EW000113
If the sidestand does not move
smoothly, consult a Yamaha dealer.Recommended lubricant:
Engine oil
EAU00790
Rear suspension lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Molybdenum disulfide grease
EAU02939
Front fork inspection
Visual checkEW000115
Securely support the motorcycle so
there is no danger of it falling over.
Check for scratches or damage on the
inner tube and excessive oil leakage
from the front fork.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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Operation check
1. Place the motorcycle on a level
place.
2. Hold the motorcycle in an upright
position and apply the front brake.
3. Push down hard on the handle-
bars several times and check if the
fork rebounds smoothly.
EC000098
CAUTION:
If any damage or unsmooth move-
ment is found with the front fork,
consult a Yamaha dealer.
EAU00794
Steering inspection
Periodically inspect the condition of the
steering. Worn out or loose steering
bearings may be dangerous. Place a
stand under the engine to raise the
front wheel off the ground. Hold the
lower end of the front forks and try to
move them forward and backward. If
any free play can be felt, ask a Yamaha
dealer to inspect and adjust the steer-
ing. Inspection is easier if the front
wheel is removed.
EW000115
Securely support the motorcycle so
there is no danger of it falling over.
EAU01144
Wheel bearings
If there is play in the front or rear wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer in-
spect the wheel bearings.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Battery
2. Pass through the battery case
3. Pass through the frame
4. Pass through the cable guide
5. Pass through the engine bracket
6. Battery breather hose
EAU00798
Battery
Check the level of the battery electro-
lyte and make sure that the terminals
are tight. Fill with distilled water if the
electrolyte level is low. If the motor-
cycle is equipped with optional electri-
cal accessories, the battery tends to
discharge more quickly, so be sure to
recharge it periodically.
EC000099
CAUTION:
When inspecting the battery, be
sure the breather hose is routed cor-
rectly. If the breather hose is posi-
tioned in such a way as to cause
battery electrolyte or gas to exit
onto the frame, structural and cos-
metic damage to the motorcycle can
occur.
EW000116
Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
ANTIDOTE:
lEXTERNAL: Flush with water.
lINTERNAL: Drink large quanti-
ties of water or milk. Follow with
milk of magnesia, beaten egg,
or vegetable oil. Call a physi-
cian immediately.
lEYES: Flush with water for
15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes etc.,
away. Ventilate when charging or
using in an enclosed space. Always
shield your eyes when working near
batteries. KEEP OUT OF REACH OF
CHILDREN.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Maximum level mark
2. Minimum level mark
Replenishing the battery fluid
A poorly maintained battery will cor-
rode and discharge quickly. The bat-
tery fluid should be checked at least
once a month. The level should be be-
tween the minimum level and maxi-
mum level marks. Use only distilled
water if refilling is necessary.
EC000100
CAUTION:
Normal tap water contains minerals
which are harmful to a battery;
therefore, refill only with distilled
water.Battery storage
lWhen the motorcycle will not be
used for a month or longer, re-
move the battery, fully charge it
and store it in a cool, dry place.
Completely recharge the battery
before reinstalling.
lIf the battery will be stored for
longer than two months, check the
specific gravity of the fluid at least
once a month and recharge the
battery when it is too low.
lAlways make sure the connec-
tions are correct when putting the
battery back in the motorcycle.
Make sure the breather hose is
properly connected and is not
damaged or obstructed.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Main fuse
2. Headlight fuse
3. Signaling system fuse
4. Ignition fuse
5. Spare fuse (´ 2)
EAU00818
Fuse replacement
The fuse box is located under the rider
seat. If any fuse is blown, turn off the
main switch and the switch of the circuit
in question. Install a new fuse of the
specified amperage. Turn on the
switches and check if the electrical de-
vice operates. If the fuse immediately
blows again, consult a Yamaha dealer.
EC000103
CAUTION:
Do not use fuses of higher amper-
age rating than those recommend-
ed. Substitution of a fuse of
improper rating can cause extensive
electrical system damage and pos-
sibly a fire.
Specified fuses:
Main fuse: 30 A
Headlight fuse: 15 A
Signaling system fuse: 15 A
Ignition fuse: 15 A
1. Screw (´ 2)
EAU01524
Headlight bulb replacement
This motorcycle is equipped with a
quartz bulb headlight.
If the headlight bulb burns out, replace
the bulb as follows:
1. Remove the headlight unit screws.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1. Connector
2. Bulb cover
2. Remove the connector, the head-
light unit and then the bulb cover.
1. Bulb holder
3. Turn the bulb holder counterclock-
wise to remove it and remove the
defective bulb.
EW000119
Keep flammable products and your
hands away from a bulb while it is
on, as it is hot. Do not touch a bulb
until it cools down.
4. Put a new bulb into position and
secure it in place with the bulb
holder.
1. DonÕt touch
EC000105
CAUTION:
Avoid touching the glass part of a
bulb. Keep it free from oil; other-
wise, the transparency of the glass,
life of the bulb, and luminous flux
will be adversely affected. If oil gets
on a bulb, thoroughly clean it with a
cloth moistened with alcohol or lac-
quer thinner.
5. Install the bulb cover, connector
and headlight unit.
Ask a Yamaha dealer to adjust the
headlight beam if necessary.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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1
1
1. Screw (´ 2)
EAU00855
Turn signal and taillight bulb
replacement
1. Remove the screws and the lense.
1
1. Bulb (´ 2)
2. Push the bulb inward and turn it
counterclockwise.
3. Place a new bulb in the socket.
Push the bulb inward and turn it
clockwise until it engages into the
socket.
4. Install the lense and the screws.
EC000108
CAUTION:
Do not over-tighten the screws as
the lense may break.
EAU01008
Troubleshooting
Although Yamaha motorcycles receive
a rigid inspection before shipment from
the factory, trouble may occur during
operation.
Any problem in the fuel, compression,
or ignition systems can cause poor
starting and loss of power. The trouble-
shooting chart describes a quick, easy
procedure for making checks.
If your motorcycle requires any repair,
bring it to a Yamaha dealer. The skilled
technicians at a Yamaha dealership
have the tools, experience, and know-
how to properly service your motor-
cycle. Use only genuine Yamaha parts
on your motorcycle. Imitation parts may
look like Yamaha parts, but they are of-
ten inferior. Consequently, they have a
shorter service life and can lead to ex-
pensive repair bills.

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PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU01562
Troubleshooting chart
EW000125
Never check the fuel system while smoking or in the vicinity of an open flame.
Check if there is fuel
in the fuel tank.
1. FuelEnough fuel.
No fuel.Go to compression check.
Supply fuel.
Use electric starter.
2. CompressionThere is compression.
No compression.Go to ignition check.
Ask a Yamaha dealer to
inspect.
Remove spark
plugs and
check electrode.
3. IgnitionWet.
Dry.Wipe clean with dry cloth and correct
spark gap or replace spark plugs.
Ask a Yamaha dealer to inspect.
Engine doesnÕt start, go to battery
check.
Open throttle half-way and start
the engine.
Use the electric starter.
4. BatteryEngine turns over
quickly.
Engine turns over
slowly.Battery good.
Check fluid, recharge,
check connections.
Engine doesnÕt start, ask a Yamaha
dealer to inspect.
Engine doesnÕt start, go to compression check.

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