torque YAMAHA XV535 2001 Owners Manual

6-1
6
EAU00462
6-PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00464
Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.
EW000060
WARNING
@ If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. @
EAU03713
Owner’s tool kit The tool kit is located under the pas-
senger seat. (See page 3-7 for passen-
ger seat removal procedures.)
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
NOTE:_ If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. _
EW000063
WARNING
_ Modifications not approved by
Yamaha may cause loss of perfor-
mance and render the vehicle un-
safe for use. Consult a Yamaha
dealer before attempting any chang-
es. _
1. Owner’s tool kit
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-6
6 To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if nec-
essary, adjust the gap to specifica-
tion.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tight-
en it to the specified torque.
NOTE:@ If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @4. Install the spark plug cap.
5. Install the spark plug cover by in-
stalling the screws.
a. Spark plug gap
Spark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
20 Nm (2.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-8
6 3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:@ Skip steps 4–6 if the oil filter element is
not being replaced. @
4. Remove the oil filter element cover
by removing the bolts.5. Remove and replace the oil filter
element and O-ring.
6. Install the oil filter element cover
by installing the bolts and tighten-
ing them to the specified torque.
1. Engine oil drain bolt
1. Oil filter element cover
2. Bolt (´ 3)
1. O-ring
2. Oil filter elementTightening torque:
Oil filter element cover bolt:
10 Nm (1.0 m·kg)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6
NOTE:@ Make sure that the O-ring is properly
seated. @7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
EC000067
CAUTION:@ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. @9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
EAU03714
Final gear oil The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha deal-
er check and repair the motorcycle. In
addition, the final gear oil level must be
checked and the oil changed as follows
at the intervals specified in the periodic
maintenance and lubrication chart.
EW000066
WARNING
_ l
Make sure that no foreign mate-
rial enters the final gear case.
l
Make sure that no oil gets on
the tire or wheel.
_
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kg)
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter element
replacement:
2.6 L
With oil filter element
replacement:
2.8 L
Total amount (dry engine):
3.2 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 To check the final gear oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.
NOTE:_ l
The final gear oil level must be
checked on a cold engine.
l
Make sure that the motorcycle is
positioned straight up when
checking the oil level. A slight tilt to
the side can result in a false
reading.
_2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
NOTE:_ The oil level should be at the brim of
the filler hole. _3. If the oil is below the brim of the fill-
er hole, add sufficient oil of the rec-
ommended type to raise it to the
correct level.
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.
2. Remove the oil filler bolt and drain
bolt to drain the oil from the final
gear case.
3. Install the final gear oil drain bolt,
and then tighten it to the specified
torque.
4. Add the recommended final gear
oil to the brim of the filler hole.
NOTE:_ GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used. _5. Install and tighten the filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
1. Final gear oil filler bolt
2. Correct oil level
3. Final gear oil drain bolt
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kg)
Recommended final gear oil:
Hypoid gear oil SAE 80 (API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Oil quantity:
0.19 L
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-35
6
EAU01394
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the pro-
jections mesh with the slots.
2. Lift the wheel up between the fork
legs.NOTE:_ Make sure that there is enough space
between the brake pads before insert-
ing the brake disc and that the slot in
the speedometer gear unit fits over the
retainer on the fork leg. _3. Insert the wheel axle.
4. Lower the front wheel so that it is
on the ground.5. Push down hard on the handlebar
several times to check for proper
fork operation.
6. Tighten the wheel axle to the
specified torque.
7. Install the front wheel axle pinch
bolt, and then tighten it to the
specified torque.
8. Connect the speedometer cable.
EAU01337
Rear wheel To remove the rear wheel
EW000122
WARNING
_ l
It is advisable to have a Yamaha
dealer service the wheel.
l
Securely support the motor-
cycle so that there is no danger
of it falling over.
_1. Remove the axle nut cotter pin,
and then loosen the axle nut.
1. Retainer
Tightening torque:
Wheel axle:
58 Nm (5.8 m·kg)
Tightening torque:
Front wheel axle pinch bolt:
23 Nm (2.3 m·kg)
1. Axle nut cotter pin
2. Axle nut
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-36
6
2. Disconnect the brake torque rod
from the brake shoe plate by re-
moving the cotter pin, the nut, and
the bolt.
3. Lift the rear wheel off the ground
according to the procedure on
page 6-33.
4. Remove the brake pedal free play
adjusting nut, and then disconnect
the brake rod from the brake cam-
shaft lever.
5. Remove the axle nut.6. Loosen the rear wheel axle pinch
bolt, and then pull the wheel axle
out.
7. Pull the wheel to the right to sepa-
rate it from the final gear case, and
then remove it.
1. Rear wheel axle pinch bolt
2. Brake pedal free play adjusting nut
3. Brake rod
4. Brake torque rod bolt/nut/cotter pin
5. Brake torque rod
6. Wheel axle
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PERIODIC MAINTENANCE AND MINOR REPAIR
6-37
6
EAU01406
To install the rear wheel
1. Apply a light coating of lithium-
soap-based grease to the splines
of the final gear case and wheel
hub.
2. Install the wheel by inserting the
wheel axle.
3. Install the brake rod onto the brake
camshaft lever, and then install
the brake pedal free play adjusting
nut onto the brake rod.
4. Connect the brake torque rod to
the brake shoe plate by installing
the bolt and the nut.
5. Install the rear wheel axle pinch
bolt.6. Lower the rear wheel so that it is
on the ground.
7. Tighten the axle nut, pinch bolt
and brake torque rod nut to the
specified torques.
8. Install the brake torque rod cotter
pin.
EW000124
WARNING
_ Always use a new cotter pin. _9. Adjust the brake pedal free play.
(See page 6-20 for brake pedal
free play adjustment procedures.)
EW000103
WARNING
_ After adjusting the brake pedal free
play, check the operation of the
brake light. _
EAU01008
TroubleshootingAlthough Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur dur-
ing operation. Any problem in the fuel,
compression, or ignition systems, for
example, can cause poor starting and
loss of power.
The following troubleshooting chart
represents a quick and easy procedure
for checking these vital systems your-
self. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replace-
ment parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
Tightening torques:
Axle nut:
107 Nm (10.7 m·kg)
Rear wheel axle pinch bolt:
16 Nm (1.6 m·kg)
Brake torque rod nut:
20 Nm (2.0 m·kg)
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SPECIFICATIONS
8-5
8
EAU01064
Conversion tableCS-02EAll specification data in this manual are listed in SI and
METRIC UNITS.
Use this table to convert METRIC unit data to IMPERIAL
unit data.
ExampleMETRIC MULTIPLIER IMPERIAL
** mm´ 0.03937 = ** in
2 mm´ 0.03937 = 0.08 in
Conversion tableMETRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
Torquem·kg
m·kg
cm·kg
cm·kg7.233
86.794
0.0723
0.8679ft·lb
in·lb
ft·lb
in·lb
Weightkg
g2.205
0.03527lb
oz
Speed km/h 0.6214 mi/h
Distancekm
m
m
cm
mm0.6214
3.281
1.094
0.3937
0.03937mi
ft
yd
in
in
Volume,
Capacitycc (cm3)
cc (cm3)
L (liter)
L (liter)0.03527
0.06102
0.8799
0.2199oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)
Miscellaneouskg/mm
kg/cm2
Centigrade (°
C)55.997
14.2234
9/5 + 32 lb/in
psi (lb/in
2)
Fahrenheit (°
F)
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