engine YAMAHA XV535 2000 Owner's Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2000, Model line: XV535, Model: YAMAHA XV535 2000Pages: 87, PDF Size: 17.84 MB
Page 47 of 87
L
6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
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)
Page 49 of 87
L
6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
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.
Page 50 of 87
R
6-12
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
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.
Page 51 of 87
L
6-13
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EAU01168
Idle speed adjustment
NOTE:
A diagnostic tachometer must be used
for this procedure.
1. Attach the tachometer. Start the
engine and warm it up for a few
minutes at approximately 1,000 to
2,000 r/min. Occasionally rev the
engine to 4,000 to 5,000 r/min.
The engine is warm when it quick-
ly responds to the throttle.
1. Throttle stop screw
2. Set the idle to the specified engine
speed by adjusting the throttle
stop screw. Turn the screw in di-
rectiona
to increase engine
speed and in direction b
to de-
crease engine speed.
NOTE:
If the specified idle speed cannot be
obtained by performing the above ad-
justment, consult a Yamaha dealer.Standard idle speed:
1,150 ~ 1,250 r/min
a. Free play
EAU00635
Throttle cable free play
inspection
There should be a free play of 3 ~
5 mm at the throttle grip. If the free play
is incorrect, ask a Yamaha dealer to
make this adjustment.
Page 52 of 87
R
6-14
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EAU00637
Valve clearance adjustment
The correct valve clearance changes
with use, resulting in improper fuel/air
supply or engine noise. To prevent this,
the valve clearance must be adjusted
regularly. This adjustment however,
should be left to a professional
Yamaha service technician.
EAU00647
Tires
To ensure maximum performance,
long service, and safe operation, note
the following:
Tire air pressure
Always check and adjust the tire pres-
sure before operating the motorcycle.
EW000082
Tire inflation pressure should be
checked and adjusted when the
temperature of the tire equals the
ambient air temperature. Tire infla-
tion pressure must be adjusted ac-
cording to total weight of cargo,
rider, passenger, and accessories
(fairing, saddlebags, etc. if approved
for this model), and vehicle speed.
Maximum load*220 kg (except for CH, A)
218 kg (for CH, A)
Cold tire pressure Front Rear
Up to 90 kg200 kPa
(2.00 kg/cm
2,
2.00 bar)225 kPa
(2.25 kg/cm2,
2.25 bar)
90 kg load ~
Maximum load*200 kPa
(2.00 kg/cm
2,
2.00 bar)250 kPa
(2.50 kg/cm2,
2.50 bar)
* Load is the total weight of cargo, rider, passenger
and accessories.
Page 59 of 87
L
6-21
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
lBrake fluid may deteriorate paint-
ed surfaces or plastic parts. Al-
ways clean up spilled fluid
immediately.
lHave a Yamaha dealer check the
cause if the brake fluid level goes
down.
EAU00742
Brake fluid replacement
The brake fluid should be replaced only
by trained Yamaha service personnel.
Have the Yamaha dealer replace the
following components during periodic
maintenance or when they are dam-
aged or leaking:
loil seals (every two years)
lbrake hoses (every four years)
EAU02962
Cable inspection and
lubrication
EW000112
Damage to the outer housing of ca-
bles may lead to internal rusting and
interfere with the cable movement.
Replace damaged cables as soon as
possible to prevent unsafe condi-
tions.
Lubricate the cables and cable ends. If
a cable does not operate smoothly, ask
a Yamaha dealer to replace it.
Recommended lubricant:
Engine oil
Page 60 of 87
R
6-22
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
EAU00773
Throttle cable and grip
lubrication
The throttle twist grip assembly should
be greased at the time that the cable is
lubricated, since the grip must be re-
moved to get at the end of the throttle
cable. After removing the screws, hold
the end of the cable up in the air and
put in several drops of lubricant. With
the throttle grip disassembled, coat the
metal surface of the grip assembly with
a suitable all-purpose grease.
EAU02984
Brake and shift pedal
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil
EAU02985
Brake and clutch lever
lubrication
Lubricate the pivoting parts.
Recommended lubricant:
Engine oil
Page 61 of 87
L
6-23
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
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.
Page 62 of 87
R
6-24
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
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.
Page 63 of 87
L
6-25
PERIODIC MAINTENANCE AND MINOR REPAIR
/Net/layout8/layout_G2/work/Imai_work/OM-PS/AA9149_XV535-E6/English/E-6.frame
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.