wheel YAMAHA XV535 2000 Owners Manual

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4-1
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

R
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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6-2
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00473
PERIODIC MAINTENANCE AND LUBRICATION
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)
1
*Fuel line¥ Check fuel hoses and vacuum hose for cracks or damage.
¥ Replace if necessary.ÖÖ
2 Spark plugs¥ Check condition.
¥ Clean, regap or replace if necessary.ÖÖÖ
3
*Fuel filter¥ Check condition.
¥ Replace if necessary.Ö
4
*Valves¥ Check valve clearance.
¥ Adjust if necessary.ÖÖÖ
5 Air filter¥ Clean or replace if necessary.ÖÖ
6
*Battery¥ Check electrolyte level and specific gravity.
¥ Correct or recharge if necessary.
¥ Make sure that the breather hose is properly routed.ÖÖ
7Clutch¥ Check operation.
¥ Adjust or replace cable.ÖÖÖ
8
*Front brake¥ Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)
¥ Correct accordingly.
¥ Replace brake pads if necessary.ÖÖÖ
9
*Rear brake¥ Check operation.
¥ Adjust brake pedal free play and replace brake shoes if necessary.ÖÖÖ
10
*Wheels¥ Check balance, runout, spoke tightness and for damage.
¥ Tighten spokes and rebalance, replace if necessary.ÖÖ

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6-3
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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6-9
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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6-16
PERIODIC MAINTENANCE AND MINOR REPAIR
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EAU00681
lOperating the motorcycle with
excessively worn tires decrease
riding stability and can lead to
loss of control. Have excessive-
ly worn tires replaced by a
Yamaha dealer immediately.
Brakes, tires, and related wheel
parts replacement should be
left to a Yamaha Service Techni-
cian.
lPatching a punctured tube is
not recommended. If it is abso-
lutely necessary to do so, use
great care and replace the tube
as soon as possible with a good
quality replacement.
EAU00685
Wheels
To ensure maximum performance,
long service, and safe operation, note
the following:
lAlways inspect the wheels before
a ride. Check for cracks, bends or
warpage of the wheel. Be sure the
spokes are tight and undamaged.
If any abnormal condition exists in
a wheel, consult a Yamaha dealer.
Do not attempt even small repairs
to the wheel. If a wheel is de-
formed or cracked, it must be re-
placed.
lTires and wheels should be bal-
anced whenever either one is
changed or replaced. Failure to
have a wheel balanced can result
in poor performance, adverse han-
dling characteristics, and short-
ened tire life.
lRide at moderate speeds after
changing a tire since the tire sur-
face must first be broken in for it to
develop its optimal characteristics.

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6-24
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.

L
7-1
MOTORCYCLE CARE AND STORAGE
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Care
The exposure of its technology makes
a motorcycle charming but also vulner-
able. Although high-quality compo-
nents are used, they are not all rust-re-
sistant. While a rusty exhaust pipe may
remain unnoticed on a car, it does look
unattractive on a motorcycle. Frequent
and proper care, however, will keep
your motorcycle looking good, extend
its life and maintain its performance.
Moreover, the warranty states that the
vehicle must be properly taken care of.
For all these reasons, it is recommend-
ed that you observe the following
cleaning and storing precautions.Before cleaning
1. Cover up the muffler outlets with
plastic bags.
2. Make sure that all caps and covers
as well as all electrical couplers
and connectors, including the
spark plug caps, are tightly in-
stalled.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such prod-
ucts onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.CleaningAfter normal use
Remove dirt with warm water, a neutral
detergent and a soft clean sponge,
then rinse with plenty of clean water.
Use a tooth or bottle brush for hard-to-
reach parts. Tougher dirt and insects
will come off more easily if the area is
covered with a wet cloth for a few min-
utes before cleaning.
EAU01521

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7-2
MOTORCYCLE CARE AND STORAGE
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ECA00010
CAUTION:
lAvoid using strong acidic wheel
cleaners, especially on spoked
wheels. If you do use such
products for hard-to-remove
dirt, do not leave it on any long-
er than instructed, then thor-
oughly rinse it off with water,
immediately dry the area and
apply a corrosion protection
spray.
lImproper cleaning can damage
windshields, cowlings, panels
and other plastic parts. Use
only a soft, clean cloth or
sponge with mild detergent and
water to clean plastic.
lDo not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust re-
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
lDo not use high-pressure wash-
ers or steam-jet cleaners since
they cause water seepage and
deterioration in the following ar-
eas: seals (of wheel bearings,
swingarm bearings, forks and
brakes), electric components
(couplers, connectors, instru-
ments, switches and lights),
breather hoses and vents.
lFor motorcycles equipped with
a windshield: Do not use strong
cleaners or hard sponges as
they will cause dulling or
scratching. Some cleaning
compounds for plastic may
leave scratches on the wind-
shield. Test the product on a
small hidden part of the wind-
shield to make sure they do not
leave any marks. If the wind-
shield is scratched, use a quali-
ty plastic polishing compound
after washing.
After riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on the
roads in the winter are extremely corro-
sive in combination with water, carry
out the following steps after each ride
in the rain, near the sea or on salt-
sprayed roads. (Salt sprayed in the
winter may remain on the roads well
into spring.)

L
7-5
MOTORCYCLE CARE AND STORAGE
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a. Remove the spark plug caps and
spark plugs.
b. Pour a teaspoonful of engine oil
into each spark plug bore.
c. Install the spark plug caps onto
the spark plugs and place the
spark plugs on the cylinder head
so that the electrodes are
grounded. (This will limit sparking
during the next step.)
d. Turn the engine over several
times with the starter. (This will
coat the cylinder walls with oil.)
e. Remove the spark plug caps from
the spark plugs, install the spark
plugs and then the spark plug
caps.
EWA00003
When turning the engine over, be
sure to ground the spark plug elec-
trodes to prevent damage or injury
from sparking.6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the side-
stand/centerstand.
7. Check and, if necessary, correct
the tire air pressure, then raise the
motorcycle so that both of its
wheels are off the ground. Alterna-
tively, turn the wheels a little every
month in order to prevent the tires
from becoming degraded in one
spot.
8. Cover up the muffler outlets with
plastic bags to prevent moisture
from entering.9. Remove the battery and fully
charge it. Store it in a cool, dry
place and recharge it once a
month. Do not store the battery in
an excessively cold or warm place
(less than 0ûC or more than 30ûC).
For more information, see ÒBattery
storageÓ in the chapter ÒPERIODIC
MAINTENANCE AND MINOR
REPAIRSÓ.
NOTE:
Make any necessary repairs before
storing the motorcycle.