clutch YAMAHA XV535 2001 User Guide

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-2
Checking the spark plugs .................................... 6-5
Engine oil and oil filter element ............................ 6-7
Final gear oil ........................................................ 6-9
Cleaning the air filter element ............................ 6-11
Adjusting the carburetors .................................... 6-13
Adjusting the engine idling speed ....................... 6-13
Adjusting the throttle cable free play ................... 6-14
Adjusting the valve clearance ............................. 6-14
Tires ................................................................... 6-15
Spoke wheels ..................................................... 6-17
Adjusting the clutch lever free play .................... 6-18
Adjusting the brake lever free play ...................... 6-19
Adjusting the brake pedal position and
free play ........................................................... 6-19
Adjusting the rear brake light switch ................... 6-21
Checking the front brake pads and rear
brake shoes ..................................................... 6-21
Checking the brake fluid level ............................ 6-22
Changing the brake fluid ..................................... 6-23Checking and lubricating the cables .................. 6-23
Checking and lubricating the throttle
grip and cable .................................................. 6-24
Checking and lubricating the brake and
shift pedals ...................................................... 6-25
Checking and lubricating the brake and
clutch levers ..................................................... 6-25
Checking and lubricating the sidestand ............. 6-25
Lubricating the rear suspension ........................ 6-26
Checking the front fork ....................................... 6-27
Checking the steering ........................................ 6-27
Checking the wheel bearings ............................. 6-28
Battery ............................................................... 6-29
Replacing the fuses .......................................... 6-31
Replacing the headlight bulb .............................. 6-31
Replacing a turn signal light bulb or the
tail/brake light bulb ........................................... 6-33
Supporting the motorcycle ................................ 6-33
Front wheel ....................................................... 6-34
Rear wheel ........................................................ 6-35
Troubleshooting .................................................. 6-37
Troubleshooting chart ........................................ 6-38
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-2
6
EAU03685
Periodic maintenance and lubrication chart
NOTE:_ l
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
l
From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
l
Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni-
cal skills.
_CP-03ENO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (´1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line• Check fuel hoses and vacuum hose for cracks or damage.ÖÖÖÖ Ö
2*Fuel filter• Check condition.ÖÖ
3 Spark plugs• Check condition.
• Clean and regap.ÖÖ
• Replace.ÖÖ
4*Valves• Check valve clearance.
•Adjust.ÖÖÖÖ
5 Air filter element•Clean.ÖÖ
• Replace.ÖÖ
6*Battery• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly routed.ÖÖÖÖ Ö
7Clutch• Check operation.
•Adjust.ÖÖÖÖÖ
8*Front brake• Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-4.)ÖÖÖÖÖ Ö
• Replace brake pads. Whenever worn to the limit
9*Rear brake• Check operation and adjust brake pedal freeplay.ÖÖÖÖÖ Ö
• Replace brake shoes. Whenever worn to the limit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-18
6
EAU00694
Adjusting the clutch lever free
play The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.
1. Loosen the locknut at the clutch
lever.
2. To increase the clutch lever free
play, turn the adjusting bolt in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
bolt in direction
b.3. If the specified clutch lever free
play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.
4. Fully turn the adjusting bolt at the
clutch lever in direction
a to loos-
en the clutch cable.
5. Loosen the locknut at the crank-
case.
6. To increase the clutch lever free
play, turn the adjusting nut in di-
rection
a. To decrease the clutch
lever free play, turn the adjusting
nut in direction
b.7. Tighten the locknut at the clutch
lever and the crankcase.1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play
1. Locknut
2. Clutch lever free play adjusting nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-25
6
EAU03370
Checking and lubricating the
brake and shift pedals The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
EAU03164
Checking and lubricating the
brake and clutch leversThe operation of the brake and clutch
levers should be checked before each
ride, and the lever pivots should be lu-
bricated if necessary.
EAU03165
Checking and lubricating the
sidestandThe operation of the sidestand should
be checked before each ride, and the
sidestand pivot and metal-to-metal
contact surfaces should be lubricated if
necessary.
EW000113
WARNING
@ If the sidestand does not move up
and down smoothly, have a Yamaha
dealer check or repair it. @
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
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8-1
8
EAU01038
8-SPECIFICATIONSSpecificationsCS-01E
Model XV535
Dimensions
Overall length 2,225 mm (except for N, S, SF)
2,250 mm (for N, S, SF)
Overall width 780 mm
Overall height 1,120 mm
Seat hight 720 mm
Wheelbase 1,520 mm
Ground clearance 160 mm
Minimum turning radius 2,900 mm
Basic weight (with oil and full
fuel tank)
195 kg (except for A)
197 kg (for A)
Engine
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement V-type, 2-cylinder
Displacement 535 cm
3
Bore ´ Stroke 76.0 ´ 59.0 mm
Compression ratio 9:1
Starting system Electric starter
Lubrication system Wet sumpEngine oil
Ty p e
Recommended engine oil
classification API Service SE, SF, SG type or
higher
Quantity
Without oil filter element
replacement 2.6 L
With oil filter element
replacement 2.8 L
Total amount (dry engine) 3.2 L
-20 -10 0
10 20 30
40
50 °C
SAE 10W–30
SAE 15W–40SAE 20W–40SAE 20W–50
SAE 10W–40
CAUTION:Be sure to use motor oils that do not contain anti-friction
modifiers. Passenger car motor oils (often labeled
“ENERGY CONSERVING II”) contain anti-friction additives
which will cause clutch and/or starter clutch slippage, result-
ing in reduced component life and poor engine performance.
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SPECIFICATIONS
8-2
8
Final gear oil
Type Hypoid gear oil SAE 80
(API GL4) or multigrade hypoid
gear oil SAE 80W-90
Quantity 0.19 L
Air filterDry type element
Fuel
Ty p e
Regular unleaded gasoline
Fuel tank capacity 13.5 L
Fuel reserve amount 2.5 L
Carburetor
Manufacturer MIKUNI
Model ´ quantity BDS34 ´ 2
Spark plug
Manufacturer/model NGK / BPR6ES or
DENSO / W20EPR-U
Gap 0.7–0.8 mm
Clutch typeWet, multiple-disc
Transmission
Primary reduction system Spur gear
Primary reduction ratio 1.944
Secondary reduction system Shaft drive
Secondary reduction ratio 3.071
Transmission type Constant mesh, 5-speed
Operation Left footGear ratio
1st 2.714
2nd 1.900
3rd 1.458
4th 1.167
5th 0.967
Chassis
Frame type Pressed backbone
Caster angle 31.5°
Trail 125 mm
Tires
Front
Type Tube tire
Size 3.00-19 49S
Manufacturer/
model Bridgestone / L303A
Dunlop / F14G
Rear
Type Tube tire
Size 140/90-15 M/C 70S
Manufacturer/
model Bridgestone / G508
Dunlop / K425
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10-INDEXAAir filter element, cleaning ...................... 6-11BBattery ................................................... 6-29
Brake and clutch levers, checking and
lubricating ............................................ 6-25
Brake and shift pedals, checking and
lubricating ............................................ 6-25
Brake fluid, changing ............................. 6-23
Brake fluid level, checking...................... 6-22
Brake lever...............................................3-4
Brake lever free play, adjusting .............. 6-19
Brake light switch, adjusting ................... 6-21
Brake pads and shoes, checking ........... 6-21
Brake pedal..............................................3-4
Brake pedal position and free play,
adjusting .............................................. 6-19CCables, checking and lubricating............ 6-23
Carburetors, adjusting............................ 6-13
Care.........................................................7-1
Clutch lever ..............................................3-3
Clutch lever free play, adjusting ............. 6-18
Conversion table ......................................8-5DDimmer switch .........................................3-2
EEngine break-in ....................................... 5-4
Engine oil and oil filter element ................ 6-7
Engine stop switch................................... 3-3FFinal gear oil ............................................ 6-9
Front fork, checking ............................... 6-27
Fuel ......................................................... 3-5
Fuel consumption, tips for reducing ......... 5-4
Fuel reserve switch.................................. 3-3
Fuel tank cap ........................................... 3-5
Fuses, replacing .................................... 6-31HHandlebar switches ................................. 3-2
Headlight bulb, replacing ....................... 6-31
Helmet holder .......................................... 3-9
High beam indicator light ......................... 3-1
Horn switch ............................................. 3-2IIdentification numbers ............................. 9-1
Idling speed, adjusting ........................... 6-13
Ignition circuit cut-off system.................. 3-10
Indicator lights ......................................... 3-1KKey identification number ........................ 9-1
LLight switch ..............................................3-3MMain switch ..............................................3-1
Model label ..............................................9-2NNeutral indicator light ...............................3-1PParking.....................................................5-5
Part locations ...........................................2-1
Pass switch ..............................................3-2
Periodic maintenance and lubrication
chart ......................................................6-2
Pre-operation check list ............................4-1SSafety information ....................................1-1
Seats .......................................................3-7
Passenger seat...................................3-7
Rider seat ...........................................3-8
Shifting .....................................................5-3
Shift pedal ................................................3-4
Shift points (for Switzerland only) .............5-3
Shock absorber assemblies, adjusting .....3-9
Sidestand ...............................................3-10
Sidestand, checking and lubricating .......6-25
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