engine YAMAHA XV535 2000 User Guide
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2000, Model line: XV535, Model: YAMAHA XV535 2000Pages: 87, PDF Size: 17.84 MB
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OPERATION AND IMPORTANT RIDING POINTS
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1. Turn the main switch to ÒONÓ and
the engine stop switch to Ò Ó.
2. Shift the transmission into neutral.
NOTE:
When the transmission is in neutral, the
neutral indicator light should be on. If
the light does not come on, ask a
Yamaha dealer to inspect it.
3. Turn on the starter (choke) and
completely close the throttle grip.
4. Start the engine by pushing the
start switch.
NOTE:
If the engine fails to start, release the
start switch, wait a few seconds, then
try again. Each attempt should be as
short as possible to preserve the bat-
tery. Do not crank the engine more
than 10 seconds on any one attempt.
5. After starting the engine, move the
starter (choke) to the halfway posi-
tion.
NOTE:
For maximum engine life, never accel-
erate hard with a cold engine!
6. After the engine is warm, turn off
the starter (choke) completely.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off.
EAU01258
Starting a warm engine
The starter (choke) is not required
when the engine is warm.
EC000046
CAUTION:
See the ÒEngine break-inÓ section
prior to operating the motorcycle for
the first time.
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OPERATION AND IMPORTANT RIDING POINTS
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1. Shift pedal
N. Neutral
EAU00423
Shifting
The transmission lets you control the
amount of power you have available at
a given speed for starting, accelerating,
climbing hills, etc. The use of the shift
pedal is shown in the illustration.
To shift into neutral, depress the shift
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
EC000048
CAUTION:
lDo not coast for long periods
with the engine off, and do not
tow the motorcycle a long dis-
tance. Even with gears in neu-
tral, the transmission is only
properly lubricated when the
engine is running. Inadequate
lubrication may damage the
transmission.
lAlways use the clutch when
changing gears. The engine,
transmission, and driveline are
not designed to withstand the
shock of forced shifting and
can be damaged by shifting
without using the clutch.
EAU02941
Recommended shift points
(for Switzerland only)
The recommended shift points are
shown in the table below.
NOTE:
When shifting two gears down from 4th
to 2nd, bring your motorcycle to a
speed of 35 km/h.
Acceleration shift point
(km/h)
1st®2nd
2nd®3rd
3rd®4th
4th®5th23
36
50
60
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EAU00424
Tips for reducing fuel
consumption
Your motorcycleÕs fuel consumption
depends to a large extent on your
riding style. The following tips can help
reduce fuel consumption:
lWarm up the engine before riding.
lTurn off the starter (choke) as
soon as possible.
lShift up swiftly and avoid high en-
gine speeds during acceleration.
lDo not double-clutch or rev the en-
gine while shifting down and avoid
high engine speeds with no load
on the engine.
lTurn off the engine instead of let-
ting it idle for an extended length
of time, i.e. in traffic jams, at traffic
lights or railroad crossings.
EAU00436
Engine break-in
There is never a more important period
in the life of your motorcycle than the
period between zero and 1,000 km. For
this reason we ask that you carefully
read the following material. Because
the engine is brand new, you must not
put an excessive load on it for the first
1,000 km. The various parts in the en-
gine wear and polish themselves to the
correct operating clearances. During
this period, prolonged full throttle oper-
ation, or any condition which might re-
sult in excessive heating of the engine,
must be avoided.
EAU00444
0 ~ 150 km
Avoid operation above 1/3 throttle.
Stop the engine and let it cool for 5 to
10 minutes after every hour of opera-
tion. Vary the speed of the motorcycle
from time to time. Do not operate it at
one set throttle position.
150 ~ 500 km
Avoid prolonged operation above
1/2 throttle. Rev the motorcycle freely
through the gears, but do not use full
throttle at any time.
500 ~ 1,000 km
Avoid cruising speeds in excess of
3/4 throttle.
EC000056
CAUTION:
After 1,000 km of operation, be sure
to replace the engine oil, oil filter
and final gear oil.
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1,000 km and beyond
Avoid prolonged full-throttle operation.
Vary speed occasionally.
EC000049
CAUTION:
If any engine trouble should occur
during the break-in period, consult a
Yamaha dealer immediately.
EAU00460
Parking
When parking the motorcycle, stop the
engine and remove the ignition key.
EW000058
The exhaust system is hot. Park the
motorcycle in a place where pedes-
trians or children are not likely to
touch the motorcycle. Do not park
the motorcycle on a slope or soft
ground; the motorcycle may over-
turn.
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PERIODIC MAINTENANCE AND MINOR REPAIR
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Tool kit ................................................................ 6-1
Periodic maintenance and lubrication................. 6-2
Spark plugs ........................................................ 6-5
Engine oil............................................................ 6-7
Final gear oil ....................................................... 6-9
Air filter ............................................................. 6-10
Carburetor adjustment ...................................... 6-12
Idle speed adjustment ...................................... 6-13
Throttle cable free play inspection .................... 6-13
Valve clearance adjustment ............................. 6-14
Tires ................................................................. 6-14
Wheels ............................................................. 6-16
Clutch lever free play adjustment ..................... 6-17
Front brake lever free play adjustment ............. 6-17
Rear brake pedal height and free play
adjustment ...................................................... 6-18
Brake light switch adjustment ........................... 6-19
Checking the front brake pads and
rear brake shoes ............................................ 6-19Inspecting the brake fluid level.......................... 6-20
Brake fluid replacement .................................... 6-21
Cable inspection and lubrication ....................... 6-21
Throttle cable and grip lubrication ..................... 6-22
Brake and shift pedal lubrication ....................... 6-22
Brake and clutch lever lubrication ..................... 6-22
Sidestand lubrication......................................... 6-23
Rear suspension lubrication.............................. 6-23
Front fork inspection ......................................... 6-23
Steering inspection ........................................... 6-24
Wheel bearings ................................................. 6-24
Battery............................................................... 6-25
Fuse replacement ............................................. 6-27
Headlight bulb replacement .............................. 6-27
Turn signal and taillight bulb replacement ........ 6-29
Troubleshooting ................................................ 6-29
Troubleshooting chart ....................................... 6-30
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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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* 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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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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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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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