check engine YAMAHA XV535 2000 Owners Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2000, Model line: XV535, Model: YAMAHA XV535 2000Pages: 87, PDF Size: 17.84 MB
Page 20 of 87
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INSTRUMENT AND CONTROL FUNCTIONS
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EAU00185
CAUTION:
Always wipe off spilled fuel immedi-
ately with a dry and clean soft cloth.
Fuel may deteriorate painted surfac-
es or plastic parts.
EAU00191
NOTE:
If knocking or pinging occurs, use a dif-
ferent brand of gasoline or higher oc-
tane grade.Recommended fuel:
Regular unleaded gasoline with
a research octane number of 91
or higher.
Fuel tank capacity:
Total:
13.5 L
Reserve:
2.5 L
1. Starter (choke) Ò Ó
EAU02976
Starter (choke) Ò Ó
Starting a cold engine requires a richer
air-fuel mixture. A separate starter cir-
cuit supplies this mixture.
Move in direction a
to turn on the
starter (choke).
Move in direction b
to turn off the
starter (choke).
1. Steering lock
EAU02934
Steering lock
To lock the steering
Turn the handlebars all the way to the
right and open the steering lock cover.
Insert the key and turn it 1/8 turn coun-
terclockwise. Then, push the key in
while turning the handlebars slightly to
the left and turn the key 1/8 turn clock-
wise.
Check that the steering is locked, re-
move the key and close the lock cover.
To unlock the steering
Insert the key, push it in and turn it 1/8
turn counterclockwise so that it moves
out. Then, release and remove the key.
Page 24 of 87
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INSTRUMENT AND CONTROL FUNCTIONS
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EAU00331
Sidestand/clutch switch
operation check
Check the operation of the sidestand
switch and clutch switch against the in-
formation below.
TURN THE MAIN SWITCH TO ÒONÓ
AND THE ENGINE STOP SWITCH TO
ÒÓ.
TRANSMISSION IS IN GEAR AND
SIDESTAND IS UP.
PULL IN CLUTCH LEVER AND
PUSH THE START SWITCH.
ENGINE WILL START.
CLUTCH SWITCH IS OK.
EW000045
If improper operation is noted, con-
sult a Yamaha dealer immediately.
SIDESTAND IS DOWN.
ENGINE WILL STALL.
SIDESTAND SWITCH IS OK.
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PRE-OPERATION CHECKS
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Owners are personally responsible for their vehicleÕs condition. Your motorcycleÕs vital functions can start to deteriorate
quickly and unexpectedly, even if it remains unused (for instance, if it is exposed to the elements). Any damage, fluid leak or
loss of tire pressure could have serious consequences. Therefore, it is very important that, in addition to a thorough visual in-
spection, you check the following points before each ride.
EAU00340
PRE-OPERATION CHECK LIST
ITEM CHECKS PAGE
Front brake¥ Check operation, free play, fluid level and vehicle for fluid leakage.
¥ Fill with DOT 4 (or DOT 3) brake fluid if necessary.
6-17 ~ 6-21
Rear brake¥ Check operation, condition and free play.
¥ Adjust if necessary.
Clutch¥ Check operation, condition and free play.
¥ Adjust if necessary.6-17
Throttle grip and housing¥ Check for smooth operation.
¥ Lubricate if necessary.6-13
Engine oil¥ Check oil level.
¥ Fill with oil if necessary.6-7 ~ 6-9
Final gear oil¥ Check vehicle for leakage. 6-9 ~ 6-10
Wheels and tires¥ Check tire pressure, wear, damage and spoke tightness.
¥ Tighten spokes if necessary.6-14 ~ 6-16
Control and meter cables¥ Check for smooth operation.
¥ Lubricate if necessary.6-21
Brake and shift pedal
shafts¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
Brake and clutch lever
pivots¥ Check for smooth operation.
¥ Lubricate if necessary.6-22
EAU01114
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OPERATION AND IMPORTANT RIDING POINTS
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EAU00373
lBefore riding this motorcycle,
become thoroughly familiar
with all operating controls and
their functions. Consult a
Yamaha dealer regarding any
control or function that you do
not thoroughly understand.
lNever start your engine or let it
run for any length of time in a
closed area. The exhaust fumes
are poisonous and can cause
loss of consciousness and
death within a short time. Al-
ways operate your motorcycle
in an area with adequate ventila-
tion.
lBefore starting out, always be
sure the sidestand is up. Failure
to retract the sidestand com-
pletely can result in a serious
accident when you try to turn a
corner.
EAU02997
Starting the engine
NOTE:
This motorcycle is equipped with an ig-
nition circuit cut-off system. The engine
can be started only under one of the
following conditions:
lThe transmission is in neutral.
lThe sidestand is up, the transmis-
sion is in gear and the clutch is dis-
engaged.
The motorcycle must not be ridden
when the sidestand is down.
EW000054
Before going through the following
steps, check the function of the
sidestand switch and clutch switch.
(Refer to page 3-10.)
EAU00372
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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
Page 41 of 87
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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)
Page 45 of 87
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PERIODIC MAINTENANCE AND MINOR REPAIR
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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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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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PERIODIC MAINTENANCE AND MINOR REPAIR
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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.