maintenance 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
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EW000099
lCheck the brake lever free play.
Be sure the brake is working
properly.
lA soft or spongy feeling in the
brake lever can indicate the
presence of air in the brake sys-
tem. This air must be removed
by bleeding the brake system
before the motorcycle is operat-
ed. Air in the system will cause
greatly diminished braking ca-
pability and can result in loss of
control and an accident. Have a
Yamaha dealer inspect and
bleed the system if necessary.
1. Footrest
2. Pedal height
a. Free play
EAU00711
Rear brake pedal height and
free play adjustment
EW000104
It is advisable to have a Yamaha
dealer make this adjustment.
The brake pedal height should be ad-
justed before adjusting the brake pedal
free play.
Pedal height
The brake pedal should be positioned
approximately 38 mm above the top of
the footrest.
1. Adjusting bolt
2. Locknut
1. Loosen the locknut.
2. Turn the adjusting bolt in direction
a
to raise pedal height or in direc-
tionb
to lower pedal height.
3. Tighten the locknut.
EW000105
After adjusting the pedal height ad-
just brake pedal free play.
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1. Adjusting nut
Free play
The brake pedal free play should be
adjusted to 20 ~ 30 mm at the brake
pedal end. Turn the adjusting nut on
the brake rod in direction a
to increase
free play or in direction b
to decrease
free play.
1. Brake light switch
2. Adjusting nut
EAU00713
Brake light switch adjustment
The rear brake light switch is activated
by the brake pedal and is properly ad-
justed when the brake light comes on
just before braking takes effect. To ad-
just the rear brake light switch, hold the
switch body so it does not rotate while
turning the adjusting nut. Turn the ad-
justing nut in direction a
to make the
brake light come on earlier. Turn the
adjusting nut in direction b
to make the
brake light come on later.
1. Wear indicator groove (´ 2)
2. Wear limit
EAU00720
Checking the front brake pads
and rear brake shoes
EAU01119
Front brake
Wear indicator grooves are provided
on each brake pad. These indicators
allow checking of brake pad wear with-
out disassembling the brake. Inspect
the grooves. If they have almost disap-
peared, ask a Yamaha dealer to re-
place the pads.
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1. Wear limit
2. Wear indicator
EAU00727
Rear brake
Apply the brake and inspect the wear
indicator.
If the indicator reaches the wear limit
line, ask a Yamaha dealer to replace
the shoes.
1. Minimum level mark
EAU00732
Inspecting the brake fluid
level
Insufficient brake fluid may let air enter
the brake system, possibly causing the
brakes to become ineffective.
Before riding, check that the brake fluid
is above the minimum level and fill
when necessary.
Observe these precautions:
lWhen checking the fluid level,
make sure the top of the master
cylinder is level by turning the han-
dlebars.
lUse only the designated quality
brake fluid. Otherwise, the rubber
seals may deteriorate, causing
leakage and poor brake perfor-
mance.
NOTE:
If DOT 4 is not available, DOT 3 can be
used.
lRefill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor brake performance.
lBe 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. Recommended brake fluid: DOT 4
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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
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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
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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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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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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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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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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.