battery YAMAHA XV535 2001 Owners Manual

DESCRIPTION
2-2
2
Right view11. Rear turn signal light (page 6-33)
12. Fuel sub-tank
13. Fuel tank (page 3-5)14. Front turn signal light (page 6-33)
15. Brake pedal (page 3-4)
16. Battery (page 6-29)
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3-1
3
EAU00027
3-INSTRUMENT AND CONTROL FUNCTIONS
EAU00028
Main switch The main switch controls the ignition
and lighting systems. The various main
switch positions are described below.
EAU00036
ON
All electrical systems are supplied with
power, and the engine can be started.
The key cannot be removed.
EAU00038
OFF
All electrical systems are off. The key
can be removed.
EAU00055
P (Parking)
The taillight and auxiliary light are on,
but all other electrical systems are off.
The key can be removed.
The key must be pushed in, and then
released before it can be turned to “P”.
ECA00043
CAUTION:@ Do not use the parking position for
an extended length of time, other-
wise the battery may discharge. @
EAU00056
Indicator lights
EAU00063
High beam indicator light “ ”
This indicator light comes on when the
high beam of the headlight is switched
on.
EAU00061
Neutral indicator light “ ”
This indicator light comes on when the
transmission is in the neutral position.
EAU00057
Turn signal indicator light “ ”
This indicator light flashes when the turn
signal switch is pushed to the left or right.
1. Push.
2. Release.
3. Turn.
1. High beam indicator light “ ”
2. Neutral indicator light “ ”
3. Turn signal indicator light “ ”
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PRE-OPERATION CHECKS
4-2
4
NOTE:@ Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved. @
EWA00033
WARNING
@ If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle. @Control cables• Make sure that operation is smooth.
• Lubricate if necessary.6-24
Wheels and tires• Check for damage.
• Check tire condition and tread depth.
• Check air pressure.
• Correct if necessary.6-15–6-17
Brake and shift pedals• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.6-25
Brake and clutch levers• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.6-25
Sidestand• Make sure that operation is smooth.
• Lubricate pivot if necessary.6-25–6-26
Chassis fasteners• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.—
Instruments, lights, signals
and switches• Check operation.
• Correct if necessary.—
Sidestand switch• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.3-10
Battery• Check fluid level.
• Fill with distilled water if necessary.6-29–6-30 ITEM CHECKS PAGE
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5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@ l
Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.
l
Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate ventila-
tion.
l
Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU02997*
Starting a cold engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:l
The transmission is in the neutral
position.
l
The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
@ l
Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-11.
l
Never ride with the sidestand
down.
@
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “ ”.
2. Shift the transmission into the neu-
tral position.NOTE:@ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit. @3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-6 for starter (choke) opera-
tion.)
4. Start the engine by pushing the
start switch.NOTE:@ If the engine fails to start, release the
start switch, wait a few seconds, and
then try again. Each starting attempt
should be as short as possible to pre-
serve the battery. Do not crank the en-
gine more than 10 seconds on any one
attempt. @
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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
6-29
6
EAU00798
Battery A poorly maintained battery will cor-
rode and discharge quickly. The elec-
trolyte level, battery lead connections
and breather hose routing should be
checked before each ride and at the in-
tervals specified in the periodic mainte-
nance and lubrication chart.To check the electrolyte level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:@ Make sure that the motorcycle is posi-
tioned straight up when checking the
electrolyte level. @2. Check the electrolyte level in the
battery.NOTE:@ The electrolyte should be between the
minimum and maximum level marks. @
3. If the electrolyte is at or below the
minimum level mark, add distilled
water to raise it to the maximum
level mark.
EW000116
WARNING
@ l
Electrolyte is poisonous and
dangerous since it contains sul-
furic acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and al-
ways shield your eyes when
working near batteries. In case
of contact, administer the fol-
lowing FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quan-
tities of water or milk and im-
mediately call a physician.
• EYES: Flush with water for
15 minutes and seek prompt
medical attention.
l
Batteries produce explosive hy-
drogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
1. Battery
2. Pass through the battery case.
3. Pass through the frame.
4. Pass through the guide.
5. Pass through the engine bracket.
6. Battery breather hose
1. Maximum level mark
2. Minimum level mark
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-30
6 away from the battery and pro-
vide sufficient ventilation when
charging it in an enclosed
space.
l
KEEP THIS AND ALL BATTER-
IES OUT OF THE REACH OF
CHILDREN.
@
EC000100
CAUTION:@ Use only distilled water, as tap water
contains minerals that are harmful
to the battery. @4. Check and, if necessary, tighten
the battery lead connections and
correct the breather hose routing.
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte at
least once a month and fully
charge the battery whenever
necessary.
3. Fully charge the battery before
installation.
4. After installation, make sure that
the battery leads are properly con-
nected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
EC000099
CAUTION:@ If the breather hose is positioned in
such a way that the frame is ex-
posed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external
damages. @
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-38
6
EAU01562
Troubleshooting chart
EW000125
WARNING
@ Keep away open flames and do not smoke while checking or working on the fuel system. @
Check the fuel level in
the fuel tank.1. Fuel
There is enough fuel.
There is no fuel.
Check the compression.
Supply fuel.
Operate the electric starter.2. Compression
There is compression.
There is no compression.
Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.3. Ignition
Wet
Dry
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.Open throttle halfway and operate
the electric starter.
Operate the electric starter.4. Battery
The engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the electrolyte and battery
lead connections, and charge the
battery if necessary.The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the compressoin.
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MOTORCYCLE CARE AND STORAGE
7-5
76. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
centerstand.
7. Check and, if necessary, correct
the tire air pressure, and then lift
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 the muffler outlets with plas-
tic bags to prevent moisture from
entering them.
9. Remove the battery and fully
charge it. Store it in a cool, dry
place and charge it once a month.
Do not store the battery in an ex-
cessively cold or warm place (less
than 0 °C or more than 30 °C). For
more information on storing the
battery, see page 6-30.
NOTE:@ Make any necessary repairs before
storing the motorcycle. @E_3bt.book Page 5 Thursday, September 7, 2000 10:01 AM