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Yamaha 1999 Virago 535 Owner's Manual

1. WARRANTY QUESTIONS AND ANSWERS CUSTOMER SERVICE Q What costs are my responsibility during the warranty period If your machine requires warranty service you must take it to any authorized The customer s responsibility includes all costs of normal maintenance services non Yamaha Motorcycle dealer within the continental United States Be sure to warranty repairs accident and collision damages and oil oil filters air filters spark bring your warranty registration card or other valid proof of the original date plugs and brake shoes of purchase If a question or problem arises regarding warranty first con tact the owner of the dealership Since all warranty matters are handled at Q What are some examples of abnormal strain neglect or abuse the dealer level this person is in the best position to help you If you are A These terms are general and overlap each other in areas Specific examples include still not satisfied and require additional assistance please write Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage YAMAHA MOTOR CORPORATION U S A or failure due to improper or careless transportation and or tie down If you have any CUSTOMER RELATIONS DEPARTMENT specific questions on operation or maintenance please contact your dealer for advice
2. 272 0 e 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR CONSUMER INFORMATION 7 CLEANING AND STORAGE 8 SPECIFICATIONS 9 S S BL s S B GG S a X Lp X 2 X CC UC ooo o B o SAFETY INFORMATION SAFETY INFORMATION 7 TWO WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERA TION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX PERTISE OF THE OPERATOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING HE OR SHE SHOULD 1 2 3 4 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION OBSERVE THE WARN
3. 1 Air filter case cover Excessive piston and or cylin 2 Tab 6 Pull out the air filter and tap it light der wear may result T ly to remove most of the dust and dirt Blow out the remaining dirt with compressed air as shown If the air filter is damaged replace it 5 Slide the air filter case cover so as to unhook the tab on the rear of the cover from the holder on the frame Then lift the air filter case cover upward without removing it 6 14 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Washer 2 Rubber damper 3 Spacer 000131 sure that the fuel hoses and vacuum hose are properly connect ed in place and not pinched If a hose is damaged be sure to replace it 000086 When reinstalling the fuel tank hold ing bolts make sure that the wash ers damper rubbers and spacers are positioned properly EAU00628 Carburetor adjustment The carburetors are important paris of the engine and emission control sys tem Adjusting should be left to a Yamaha dealer with the professional knowledge specialized data and equipment to do so properly 6 15 a Free play EAU00635 Throttle cable free play inspection There should be a free play of 3 5mm 0 12 0 20 in at the throttle grip If the free play is incorrect ask a Yamaha dealer to make this adjust ment PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0637 Valve clearance adjustment The correct valve clear
4. bas rao esatto us adde 6 27 Fuse 6 29 Headlight bulb replacement 6 29 Turn signal and taillight bulb replacement 6 31 Troubleshooting 6 31 Troubleshooting 6 32 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0462 EAUO0463 Periodic inspection adjustment and lubrication will keep your motorcycle in the safest and most efficient condition possible Safety is an obligation of the motorcycle owner The most important points of motorcycle inspection adjust ment and lubrication are explained in the following pages Maintenance replacement or re pair of the emission control devices and systems may be performed by any repair establishment or individ ual using any part which is certified if applicable If you are not familiar with motor cycle service this work should be done by a Yamaha dealer 000060 EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROP ER ENGINE OPERATION AND MAXI MUM PERFORMANCE IN THE FOLLOWING TABLES OF PERIODIC MAINTENANCE THE SERVICES RE
5. 49 mos 55 000km 34 800 mi or 55 mos 61 000km 38 600 61 9 6 YAMAHA MOTOR CORPORATION U S A CONSUMER INFORMATION STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants each new model Yamaha motorcycle will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modi
6. Starting a warm engine Starting and warming up a cold engine Steering inspection 2 Steering lock Storage Street and enduro motorcycle limited warranty T Throttle cable and grip lubrication Throttle cable free play inspection To decelerate start out and accelerate Troubleshooting Troubleshooting chart Turn indicator light Turn signal and taillight bulb replacement Turn signal switch V Valve clearance adjustment Vehicle identification number Wheel bearings Wheels Y PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual YAMAHA MOTOR LTD LIT 11626 12 28
7. 7 000 km 4 400 mi or 7 months 3 13 000 km 19 000 km 25 000 31 000 km 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or or 13 months 19 months 25 months 31 months Warm up engine before draining See page 6 10 Replace Clean with compressed air Replace if necessary Adjust free play Replace pads if necessary Front Replace shoes if necessary Rear Adjust free play Final gear oil Check oil level and leakage Replace every 24 000 km 15 200 mi or 24 months SAE 80 API GL 4 hypoid gear oil Replace Control and meter cable Swingarm pivot bearing Apply chain lube thoroughly Yamaha chain and cable lube or SAE 10W30 motor oil Check bearing assembly for looseness Moderately repack every 24 000 km 15 200 mi Molybdenum disulfide grease Brake Clutch lever pivot shaft Apply chain lube lightly Yamaha chain and cable lube or SAE 10W30 motor oil PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS 1 2 ROUTINE 1 000 km 7 000 km 13 000 km 19 000 25 000 31 000 km 600 4 400 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or or or or 1 month 7 months 13 months 19 months 25 months 31 months Yamaha chain and cable lube or SAE 10W30 Y y Brake pedal Lubricate shift p
8. Box 6555 E Cypress California 90630 Q Does the warranty cover incidental costs such as towing or transportation due to a failure When contacting Yamaha Motor Corporation U S A don t forget to include No The warranty is limited to repair of the machine itself any important information such as names addresses model V I N frame f number dates and receipts Q May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them A Yes if you are a qualified mechanic and follow the procedures specified in the Owner s SHSNOEDIOADDRESS and Service Manual We do recommend however that items requiring special tools The federal government requires each manufacturer of a motor vehicle to or equipment be done by Yamaha Motorcycle dealer maintain a complete up to date list of all first purchasers against the Q Willthe warranty be void or cancelled if i do not operate or maintain my new motor possibility of a safety related defect and recall This list is compiled from cycle exactly as specified in the Owner s Manual the purchase registrations sent to Yamaha Motor Corporation U S A by the A No The warranty on a new motorcycle cannot be voided or cancelled However selling dealer at the time of your purchase if a particular failure is caused by operation or maintenance other than as shown If you should move after you have purchased your new motorcycle please in the Owner
9. 2 Wear a face shield or goggles Wind on your unprotected eyes could contribute to an impairment of vi sion which could delay seeing a hazard 3 The use of heavy boots jacket trousers gloves etc is effective in preventing or reducing abrasions or lacerations 4 Never wear loose fitting clothing It could catch on the control levers footrests or wheels and cause in jury or accident 5 Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modification Modifications made to the motorcycle not approved by Yamaha or the removal of original equipment may render your motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle illegal to use Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the machine is changed To avoid the possibility of an accident extreme caution should be used if adding cargo or accessories to your motorcycle Use extra care if riding a motorcycle which has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding acces sories to your motorcycle Loading The total weight of the operator passenger accessories and cargo must not exceed th
10. 6 9 Engine Oil cbe mirentur 6 10 Final gear oll cicer rtis ree me Ett 6 12 E 6 13 Carburetor 6 15 Throttle cable free play inspection 6 15 Valve clearance adjustment 6 16 i 2e c 6 16 Wheels 6 18 Accessories or replacement parts 6 19 Clutch lever free play adjustment 6 19 Front brake lever free play adjustment 6 20 Rear brake pedal height and free play adjustment esesssssseeseeeeee tenent ENANCE AND MINOR REPAIR Brake light switch adjustment Checking the front brake pads and rear brake 6 22 Inspecting the brake fluid 6 23 Brake fluid 6 24 Cable inspection and lubrication 6 24 Throttle cable and grip lubrication 6 24 Brake and shift pedal lubrication 6 25 Brake and clutch lever lubrication 6 25 Sidestand 6 25 Front fork inspection esses 6 26 Steering inspection 3 3 6 26 Wheel bearings eese 6 27
11. 000158 Front brake lever The front brake lever is located on the right handlebar Pull it toward the han dlebar to apply the front brake 3 4 1 Rear brake pedal EAU00162 Rear brake pedal The rear brake pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake INSTRUMENT AND CONTROL FUNCTIONS 1 Open EAU00167 Fuel tank cap To open Insert the key and turn it 1 4 turn clock wise The lock will be released and the cap can be opened To close Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original posi tion NOTE This tank cap cannot be closed unless the key is in the lock The key cannot be removed if the cap is not locked properly Be sure the cap is properly installed and locked in place before riding the motorcycle 000023 3 5 1 Filler tube 2 Fuel level EAU01183 Fuel Make sure there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustra tion Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bot tom of the filler tube or it may over flow when the fuel heats up later and expands EW000130 INSTRUMENT AND CONTROL FUNCTIONS EAUO0185 Always wipe off spilled fuel immedi ately with a dry and clean soft cloth Fuel may deteriorate painted su
12. 219 kg 483 Ib XV535C SPECIFICATIONS Air pressure cold tire Up to 90 kg load Front Rear 90 kg load maximum load Front Rear Load is total weight of cargo rider passenger and accessories Wheels Type Front Rear Size Front Rear Brakes Front Type Operation Fluid Rear Type Operation 200 kPa 2 00 kgf cm 29 psi 225 kPa 2 25 kgf em 33 psi 200 kPa 2 00 kgf cm 29 psi 250 kPa 2 50 kgf cm 36 psi Spoke Spoke 19 x MT1 85 15M C x MT3 00 Single disc brake Right hand operation DOT 4 or DOT 3 Drum brake Right foot operation Suspension Front Type Rear Type Shock absorbers Front Rear Wheel travel Front Rear Electrical system Ignition system Charging system Type Standard output Battery Type Voltage capacity Headlight type Telescopic fork Swingarm Coil spring oil damper Coil spring oil damper 150 mm 5 9 in 85 mm 3 3 in T C I digital A C magneto 14 V 24 A 5 000 r min GM12AZ 3A 2 12 V 12 AH Bulb type SPECIFICATIONS eee eee Bulb voltage wattage x quantity Headlight 12V 65 W 60W x 1 Tail brake light 12V 8W 27Wx2 Front flasher position light 12V 27W 8Wx2 Rear flasher light 12 27 2 Meter light 14V 3Wx1 Neutral indicator light 14V 8W x1 High beam indicator light 12V 17Wx1 Turn indicator light 14V 3W x1 Fuses Main fuse 30A Ignition fuse 15A Signaling system fuse 15A Headlight fuse 15A Identification numbers
13. 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 1 Before cleaning the motorcycle a Block off the end of the exhaust pipes to prevent water entry a plastic bag and strong rubber band may be used b Make sure the spark plugs and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreas er to wheel axles Rinse the dirt and degreaser off with a garden hose Use only enough pressure to do the job EAUO1010 000111 Excessive hose pressure may cause water seepage and deterioration of wheel bearings front fork brakes transmission seals and electrical parts Many expensive repair bills have re sulted from improper high pressure detergent applications such as those available in coin operated car washers 4 After riding on salted roads wash the motorcycle with cold water im mediately Do not use warm water as it increases the chemical reac tion of the salt 5 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild deter gent type soap An old toothbrush or bottle brush is handy for hard to get at places 6 Rinse the motorcycle off immedi ately with clean water and dry all surfaces with a chamo
14. LATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPE CIALIZED DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES 1 Tool kit EAUO0468 Tool kit The service information included in this manual is intended to provide you the owner with the necessary information for completing some of your own pre ventive maintenance and minor re pairs The tools provided in the owner s tool kit are to assist you in the perfor mance of periodic maintenance How ever some other tools such as a torque wrench are also necessary to perform the maintenance correctly NOTE If you do not have necessary tools re quired during a service operation take your motorcycle to a Yamaha dealer for service Modifications to this motorcycle not approved by Yamaha may cause loss of performance excessive emissions and render it unsafe for use Consult a Yamaha dealer be fore attempting any changes 000062 PERIODIC MAINTENANCE AND MINOR REPAIR 6 2 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0471 PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL SYSTEM INITIAL ODOMETER READINGS 2 3 ROUTINE 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or or or or 1 month 7 months 13 months 19 months 25 months 31 months Check and adjust valve clea
15. and Cable Lube Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil or SAE 10W30 motor oil or SAE 10W30 motor oil 000113 If the sidestand does not move smoothly consult a Yamaha dealer 6 25 PERIODI C MAINTENANCE AND MINOR REPAIR EAU00793 Front fork inspection Securely support the motorcycle so there is no danger of it falling over 000115 Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork 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 000098 If any damage unsmooth move ment is found with the front fork consult a Yamaha dealer 6 26 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 Securely support the motorcycle so there is no danger of it falling over 000115 PERIODIC MAINTENANCE AND MINOR REPAIR E
16. coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service EAUO1063 We urge you to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 9 10 CONSUMER INFORMATION Y YAMAHA EXTENDED SERVICE A Accessories or replacement parts B Brake and clutch lever lubrication Brake and shift pedal lubrication Brake fluid replacement Brake light switch adjustment C Cable inspection and lubrication _ Canister for California only Carburetor adjustment _ Checking the front brake pads and rear brake shoes _ Cleaning Clutch lever Clutch lever
17. repair 000044 INSTRUMENT AND CONTROL FUNCTIONS EAU00331 Sidestand clutch switch SIDESTAND 15 DOWN operation check Check the operation of the sidestand switch and clutch switch against the in NGINE WILL STALL formation below SIDESTAND SWITCH IS OK TURN THE MAIN SWITCH TO AND THE ENGINE STOP SWITCH TO 277000045 RUN A WARNING a If improper operation is noted con TRANSMISSION IS IN GEAR AND sult a Yamaha dealer immediately SIDESTAND IS UP PUSH THE START SWITCH PULL IN CLUTCH LEVER AND ENGINE WILL START 1 CLUTCH SWITCH IS Y 2 222 n Pre operation check list Mum a o 2 us ux m 22 2 2 7 U Qi S 22222 oo 4 2 2000400 222 Ae ju m moo 7777 2 27 2 d 2 2 2 27222 2 2 22 44 7244 3 T 4424 0 2 ve 1 D qu 22 1 4 _ 222 LL 2 2 222 _ _ PRE OPERATION CHECKS odd Owners are personally responsible for their vehicle s condition Your motorcycle s vital functions can start to deteriorate quickly and unexpectedly ev
18. switch wait a few seconds then try again Each attempt should be as short as possible to preserve the bat tery Do not crank the engine more than 10 seconds on any one attempt 5 After starting the engine move the starter choke back to the halfway position NOTE For maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine 6 After warming up the engine turn off the starter choke completely 5 3 NOTE e The engine is warm when it re sponds normally to the throttle with the starter turned off To avoid the possibility of excessive ex haust emissions never leave the starter circuit on longer than nec essary The length of time the starter is needed depends upon the ambient temperature Warm ambient temperatures above 10 C 50 F require about 7 sec onds of starter use Cold ambient temperatures below 10 C 50 F require about 35 seconds with the starter turned on then about 2 5 minutes with the starter in the halfway position e For maximum engine life always warm up the engine before start ing off Never accelerate hard with a cold engine EAU01258 Starting a warm engine The starter choke is not required when the engine is warm EC000046 See the Engine break in section prior to operating the motorcycle for the first time OPERATION AND IMPORTANT RIDING POINTS 1 Shift pedal N Neutral EAU00423
19. the space pro vided This information will be needed to order spare parts from your Yamaha dealer 9 2 CONSUMER INFORMATION EAUO1051 REPORTING SAFETY DEFECTS If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immedi ately inform the National Highway Traffic Safety Administration NHTSA in addition to notifying YAMAHA MOTOR CORP U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or YAMAHA MOTOR CORP U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other informa tion about motor vehicle safety from the Hotline 9 3 CONSUMER INFORMATION EAU01053 MOTORCYCLE NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or w
20. AUO1144 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 Battery Pass through the battery case Pass through the cable guide 1 2 3 Pass through the frame 4 5 Pass through the engine bracket EAUO0798 Battery Check the level of the battery electro lyte and make sure that the terminals are tight Fill with distilled water if the electrolyte level is low If the motor cycle is equipped with optional electri cal accessories the battery tends to discharge more quickly so be sure to recharge it periodically 6 27 000099 When inspecting the battery be sure the breather hose is routed cor rectly If the breather hose is posi tioned in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cos metic damage to the motorcycle can occur EW000116 Battery electrolyte is poisonous and dangerous causing severe burns etc It contains sulfuric acid Avoid contact with skin eyes or clothing ANTIDOTE EXTERNAL Flush with water INTERNAL Drink large quanti ties of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physi cian immediately EYES Flush with water for 15 minutes and get prompt medi cal attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging o
21. ESCRIPTION Right view 10 Rear flasher light page 6 31 13 Front flasher position light 11 Fuel tank 14 Rear brake pedal page 3 4 12 Sub fuel tank page 3 5 15 Battery page 6 27 2 2 DESCRIPTION Controls Instruments 16 Clutch lever 17 Speedometer 18 Front brake lever 19 Throttle grip 20 Right handlebar switches 21 Left handlebar switches page 3 3 page 3 2 page 3 4 page 6 15 page 3 3 page 3 2 2 3 ae 114 1 22207227222 2 11 114 2 2222 2 s 228 3 2 Main switch Indicator lights Speedometer Handlebar switches Clutch lever 972 Shift pedal Mo tisse metere Front brake lever Rear brake pedall cssccssccssssssensecsstesssssssscossosscsarcsassersensceessenees 3 4 aia qc uS Fuel Steering lock E NIS ET duse es Lus ET Helmet holder 358 Rear shock absorber adjustment sess 3 9 Sidestand ECTS Starter choke Bretoscsssnosssasesssensoveeeesusoossnheex INSTRUMENT AND CONTROL FUNCTIONS EAU00028 Main switch The main
22. INGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANUAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AN D OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding Always make pre operation checks Careful checks may help prevent an accident This motorcycle is designed to carry the operator and a passenger The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of au tomobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore a Wear a brightly colored jacket b Use extra caution when you approach and pass through intersections since intersections are the most likely places for motorcycle accidents c Ride where other motorists can see you Avoid riding in another motorist s blind spot 7 8 SAFETY INFORMATION Many accidents involve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle license a Make sure you are qualified Also only lend your motorcycle to experienced operators b Know your skills and limits Staying within your limits may help you to avoid an accident c We recommend that you practice riding your motorcy
23. ND MINOR REPAIR Final gear case capacity 0 19 L 0 17 Imp qt 0 20 US qt Recommended oil SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions NOTE 225 22 222 GL 4 is a quality and additive rating Hypoid gear oils rated GL 5 or GL 6 may also be used 5 Reinstall and tighten the filler bolt to the specified torque Tightening torque Oil filler bolt 23 Nm 2 3 m kg 17 ft lb 6 After replacing the final gear oil be sure to check for oil leakage 1 Fuel tank 2 Bolt x 3 001473 Air filter The air filter should be cleaned at the specified intervals It should be cleaned more frequently if you are riding in un usually wet or dusty areas 1 Remove the seats 2 Remove the fuel tank bolts 6 13 1 Screw 3 Lift the front of the fuel tank up ward and position it away from the air filter Do not remove the fuel tank e Support the fuel tank carefully during this procedure e Do not tilt the fuel tank too much or pull it too hard be cause the fuel hose connec tions may become loose causing fuel leakage EWO000071 4 Remove the air filler case cover Screw PERIODIC MAINTENANCE AND MINOR REPAIR 7 Reassemble by reversing the re moval procedure EC000082 e Make sure the air filter is prop erly seated in the air filter case e The engine should never be run without the air filter installed
24. NTENANCE AND MINOR REPAIR EAU01008 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during operation Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The trouble 1 Screw x 2 1 Bulb shooting chart describes a quick easy Mw 2 Push the bulb inward and turn it Procedure for making checks Turn signal and taillight bulb 5uhtercloekise If your motorcycle requires any repair replacement Place a new bulb in the socket ONG itto a Yamaha dealer The skilled 1 Remove the screws and the lense Push the bulb inward and tum it technicians at a Yamaha dealership have the tools experience and know socket how to properly service your motor 4 Install the lense and the screws cycle Use only genuine Tamana parts your motorcycle Imitation parts may look like Yamaha parts but they are of ten inferior Consequently they have a shorter service life and can lead to ex pensive repair bills clockwise until it engages into the Do not over tighten the screws as the lense may break 6 31 PERIODIC MAINTENANCE AND MINOR REPAIR Troubleshooting chart A WARNING EAUO1297 EW000125 G Never check the fuel system while smoking or in the vicinity of an open flame 1 Fuel Check if there is fuel Enough f
25. Shifting The transmission lets you control the amount of power you have available at a given speed for starting accelerating climbing hills etc The use of the shift pedal is shown in the illustration To shift into neutral depress the shift pedal repeatedly until it reaches the end of its travel then raise the pedal slightly 5 4 000048 Do not coast for long periods with the engine off and do not tow the motorcycle a long dis tance Even with gears in neu tral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission Always use the clutch when changing gears The engine transmission and driveline are not designed to withstand the shock of forced shifting and can be damaged by shifting without using the clutch OPERATION AND IMPORTANT RIDING POINTS EAU01205 To start out and accelerate 1 2 Pull the clutch lever to disengage the clutch Shift into first gear The neutral in dicator light should go out Open the throttle gradually and at the same time release the clutch lever slowly At the recommended shift point in the table on page 5 5 close the throttle and at the same time quickly pull in the clutch lever Shift into second gear Be careful not to shift into neutral Open the throttle part way and gradually release the clutch lever Follow the same procedure when shifting to the next higher ge
26. This motorcycle is equipped with an ig nition circuit cut off system The engine can be started only under the following conditions e The transmission is in neutral e The 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 Before going through the following steps check the function of the sid estand switch and clutch switch Refer to page 3 10 EW000054 OPERATION AND IMPORTANT RIDING POINTS ENGINE STOP SWITCH TO RUN THE MAIN SWITCH ON AND wE V IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN SIDESTAND IS UP PUSH THE START SWITCH PULL IN THE CLUTCH LEVER AND PUSH THE ENGINE WILL START START SWITCH ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN OPERATION AND IMPORTANT RIDING POINTS 1 Turn the main switch to ON and the engine stop switch to RUN 2 Shift the transmission into neutral NOTE When the transmission is in neutral the neutral indicator light should be on If the light does not come on ask a Yamaha dealer to inspect it 3 Turn on the starter choke and completely close the throttle grip 4 Start the engine by pushing the start switch NOTE If the engine fails to start release the start
27. YAMAHA OWNER S MANUAL VIRA XV535L XV535LC INTRODUCTION EAU00002 Congratulations on your purchase of the Yamaha XV535 XV535C This model is the result of Yamaha s vast experience in the production of fine sporting touring and pac esetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions about the operation or main tenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the motorcycle s performance or economy of opera tion To maintain these high standards it is important that you and your dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual IMPORTANT MANUAL INFORMATION EAUO0003 Particularly important information is distinguished in this manual by the following notations AN The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person inspecting or rep
28. airing the motorcycle sj A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold e Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If there is any question con cerning this manual please consult your Yamaha dealer IMPORTANT MANUAL INFORMATION Ewooo000 ee ae ee ee PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED A SATISFAC TORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE AFFIX DEALER EAU01399 XV535L XV535LC OWNER S MANUAL 1998 by Yamaha Motor Corporation U S A 1st Edition July 1998 All rights reserved Any r
29. ance 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 EAUO0645 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 A WARNING 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 6 16 220 kg 485 Ib XV535 Maximum load 219 kg 483 Ib 535 Cold tire pressure Front Rear 200 kPa 225 kPa 2 00 kgf cm 2 25 kgf cm 29 psi 33 psi 200 kPa 250 kPa 2 00 kgt cm 2 50 kgf cm 29 psi 36 psi Up to 90 kg 198 Ib load 90 kg 198 Ib load Maximum load Load is the total weight of cargo rider passenger and accessories PERIODIC MAINTENANCE AND MINOR REPAIR 000083 Proper loading of your motorcycle is important for several characteris tics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heaviest it
30. antity Total amount 3 2 L 2 8 Imp qt 3 4 US qt Periodic oil change 2 6 L 2 3 Imp qt 2 7 US qt With oil filter replacement 2 8 L 2 5 Imp qt 3 0 US qt PERIODIC MAINTENANCE AND MINOR REPAIR 000066 2 Remove the 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 Do not putin any chemical addi tives Engine oil also lubricates the clutch and additives could cause clutch slippage e Be sure no foreign material en ters the crankcase Oil replacement 1 Place an oil pan under the final 8 Start the engine and warm it up for 1 Final gear oil drain plug HE 8 HUE a few minutes While warming up deer a or 2 Remove the oil filler bolt and drain check for oil leakage If oil leakage 4 Aaah level plug mun on i is found stop the engine immedi e 3 Reinstall and tighten the drain plug ately and check for the cause Final gear oil to the specified torque 000066 Tightening torque Drain plug 23 Nm 2 3 m kg 17 ft lb Do not let foreign material enter the final gear case Be sure oil does not get on the tire or wheel 4 Fill the gear case to the brim of the filler hole with the recommended Oil level inspection oil 1 Place the motorcycle on a level place and hold it in an upright posi tion The engine should be cool at ambient temperature 6 12 PERIODIC MAINTENANCE A
31. ar Always shift gears at the recom mended shift points EAU00427 To decelerate 1 Apply both the front and the rear brakes at the same time to slow the motorcycle When the motorcycle reaches 20 km h 12 5 mish shift into first gear Any time the engine is about to stall or runs very roughly pull in the clutch and use the brakes to stop When the motorcycle is almost completely stopped shift into neu tral The neutral indicator light should come on EAUO0429 Recommended shift point Acceleration shift point km h mi h Deceleration shift point km h mi h 151 2nd 2nd 3rd 4th 4th 5th 16 9 9 24 14 9 32 19 9 40 24 9 20 12 5 20 12 5 20 12 5 20 12 5 EAU00436 Engine break in There is never a more important period in the life of your motorcycle than the period between zero and 1 000 km 600 mi For this reason we ask that you carefully read the following materi al Because the engine is brand new you must not put an excessive load on it for the first 1 000 km 600 mi The various parts in the engine wear and polish themselves to the correct oper ating clearances During this period prolonged full throttle operation or any condition which might result in exces Sive heating of the engine must be avoided OPERATION AND IMPORTANT RIDING POINTS EAU00444 0 150 km 0 90 mi Avoid operation above 1 3 throttle Stop the engine and le
32. cement should also be left to a Yamaha dealer Patching 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 Always 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 Tires 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 Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteristics 6 18 PERIODIC MAINTENANCE AND MINOR REPAIR 000691 Accessories or replacement parts This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your mo torcycle should be designed specifically for it and they must be securely mounted to maintain the inherent stability of the original de sign Genuine Yamaha Parts and Accessories are designed and t
33. cle where there is no traffic until you have be come thoroughly familiar with your motorcycle and all of its controls Many motorcycle accidents have been caused by motorcycle operator errors A typical error made by the operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars and both feet on the operator footrests during operation to maintain control of the motorcycle b The passenger should always hold on to the operator or the seat strap or grab bar if the motorcycle is so equipped with both hands and keep both feet on the passenger footrests Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or drugs This motorcycle is designed for on road use only It is not suitable for off road use Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety hel met is the single most critical factor in the prevention or reduction of head injuries 1 Always wear an approved helmet SAFETY INFORMATION
34. e maximum load limit of XV535 485 Ib 220 kg XV535C 483 Ib 219 kg SAFETY INFORMATION When loading within these weight limits keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or in stability Shifting weights can create a sudden imbalance Make sure that accessories and cargo are securely attached to the motorcycle before riding Recheck accessory mounts and cargo restraints frequently Never attach any large or heavy items to the handlebars front forks or front fender These items in cluding such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steer ing response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the prop er selection installation and use of non Yamaha accessories You should use extreme caution when se lecting and installing any accessories Keep in mind these guidelines for mounting accessories in addition to those provided under LOADING 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Care fully inspect the accessory before using it to make sure it does not in any
35. edal shaft Apply chain lube lightly Sidestand pivot lubricate lube or SAE 10W30 Check operation and Yamaha chain and cable J 1 J Apply chain lube lightly motor oil Front fork oil Check operation and 5 leakage Check bearing assembly for looseness Lithium soap base Moderately repack grease every 24 000 km 15 200 mi Check bearing for smooth rotation Check specific gravity Battery and breather pipe for proper operation Checkandcleanor replace if necessary Steering bearings Wheel bearings Sidestand switch Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer NOTE For farther odometer reading beyond those listed repeat the above maintenance at the period established 1 Every 6 000 km 3 800 mi and 2 Every 12 000 km 7 600 mi and 3 Every 24 000 km 15 200 mi intervals 6 6 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01450 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake system When disassembling the master cylinder or caliper cylinder 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 cylinder every two years Replace the brake hoses every four years o
36. ems close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure the total weight of the cargo rider passenger and accessories fairing saddlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury 1 Side wall 2 Wear indicator a Tread depth Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the side wall is cracked con tact a Yamaha dealer immediately and have the tire replaced 6 17 FRONT Manufacturer Size Type Bridgestone 3 00 19 49S L303A 3 00 19 495 F14G REAR Type Manufacturer Size Bridgestone 140 90 15 M C 70S G508 Duniop 140 90 15 M C 705 K425 Minimum tire tread depth front and rear 1 0 mm 0 04 in A WARNING It is dangerous to ride with a PERIODIC MAINTENANCE AND MINOR REPAIR _ EAUOO0680 worn out tire When a tire tread begins to show lines have a Yamaha dealer replace the tire immediately Brakes tires and related wheel parts repla
37. en if it remains unused for instance if itis 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 PRE OPERATION CHECK LIST ITEM ROUTINE PAGE Front brake 1 Check operation free play fluid level and fluid leakage Fill with DOT 4 or DOT 3 brake fluid if necessary Bo 6 24 Check operation and free play Rear brake Adjust if necessary Check operation condition and clutch lever free play 3 Clutch Adjust if necessary 6 19 4 Engine oil Check engine oil level fill engine with oil if necessary 6 10 6 12 Final gear oil Check for leakage 6 12 6 13 Throttle Check for smooth operation 6 15 Check fluid level fill with distilled water if necessary 6 27 6 28 EAU00340 Lights signals and 5 29 6 switches Check operation 6 29 6 31 Wheels Tires Check tire pressure wear damage and spoke tightness 6 16 6 18 Check the tightness of ali chassis nuts bolts and screws Adjust if necessary Chassis fasteners PRE OPERATION CHECKS Pre operation checks should be made each time the motorcycle is used Such an inspection can be thoroughly accom plished in a very short time and the added safety it assures is more than worth
38. eprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 12 28 20 1 SAFETY INFORMATION 2 DESCRIPTION t 27 c 4 Qo a 2 c d oe _ i 2 oe o D 777 ud 2 212 v v 22 4 _ e 722 22 s oe 2 v 2 2222 E _ _ ____ i o _______ p ao Uis gt ono d o o S S 9 o o p o gt pu _ p S US C UU v C _ o C 5 17 22 2 4 e SO lt UU 9 J S S9 SS v JS Vj DE 12 2 2 2 qum 1
39. er adjusting the pedal height ad just brake pedal free play 000105 6 21 1 Adjusting nut Free play The brake pedal free play should be adjusted to 20 30 mm 0 8 1 2 in at the brake pedal end Turn the adjusting nut on the brake rod in direction 8 to increase free play or in direction to decrease free play 1 Brake light switch 2 Adjusting nut EAU00713 Brake light switch adjustment The rear brake light switch is activated by the brake pedal and is properly ad justed when the brake light comes on just before braking takes effect To ad just the rear brake light switch hold the switch body so it does not rotate while turning the adjusting nut Turn the ad justing nut in direction to make the brake light come on earlier Turn the adjusting nut in direction D to make the brake light come on later PERIODIC MAINTENANCE AND MINOR REPAIR 1 Wear indicator groove a Wear limit EAUO0720 Checking the front brake pads and rear brake shoes EAUO1119 Front brake Wear indicator grooves are provided on each brake pad These indicators allow checking of brake pad wear with out disassembling the brake Inspect the grooves If they have almost disap peared ask a Yamaha dealer to re place the pads 6 22 1 Wear limit 2 Wear indicator EAUO0727 Rear brake Apply the brake and inspect the wear indicator If the indicator reaches the wear limit line ask a Yamaha dealer t
40. erclockwise 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 release the lock Insert the key push it in and turn it 1 8 turn counterclockwise so that it moves out Then release and remove the key 1 Seat lock 2 Open EAU00249 Seat Passenger seat To remove the passenger seat insert the key in the lock and turn it clockwise 3 7 1 Projection 2 Seat holder To reinstall the passenger seat insert the projection on the rear of the seat into the seat holder then push down the seat 1 Bolt x 2 Rider seat To remove the rider seat first remove the passenger seat then the two rider seat bolts INSTRUMENT AND CONTROL FUNCTIONS 1 Seat holder x 2 2 Projection x 2 To reinstall the rider seat insert the projections on the front of the seat into the seat holders and tighten the bolts Then reinstall the passenger seat NOTE Make sure that the seat is securely fit ted 3 8 1 Open EAUO0260 Helmet holder To open the helmet holder insert the key in the lock and turn it as shown To lock the helmet holder replace the holder in its original position Never ride with a helmet in the hel met holder The helmet may hit ob jects causing loss of control and possibly an accident EW000030 INSTRUMENT AND CONTROL FUNCTIONS 1 Spr
41. est ed to be compatible with your mo torcycle Please consider Genuine Yamaha Parts and Accessories be fore making an accessory purchase Use of non Yamaha approved parts or accessories may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of parts or accessories man ufactured by other companies Yamaha cannot be held liable for 000098 any consequences caused by the use of items which have not been approved by Yamaha 6 19 1 Locknut 2 Adjusting bolt c Free play EAU00604 Clutch lever free play adjustment The clutch lever free play should be ad justed to 10 15 mm 0 39 0 59 in 1 Loosen the locknut at the clutch le ver 2 Turn the adjusting bolt at the clutch lever in direction to in crease free play or in direction to decrease free play 3 Tighten the locknut at the clutch lever 1 Locknut 2 Adjusting nut if the specified free play cannot be ob tained proceed with the following steps 4 5 Loosen the locknut at the clutch le ver Turn the adjusting bolt at the clutch lever in direction to loos en the cable Loosen the locknut at the crank case side Turn the adjusting nut at the crankcase in direction to in crease free play or in direction to decrease free play Tighten the locknut at the crank case and the clutch lever PERIODIC MAINTENANCE AND MINOR REPAIR 1 Adjusting bol
42. fication to original parts moan SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehi cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standard
43. free play adjustment Controls Instruments D Dimmer switch E Engine break in Engine stop switch F Final gear oil Front brake lever Front brake lever free play adjustment Front fork inspection Fuel reserve switch Fuel tank cap Fuse replacement G Gasoline and exhaust gas General maintenance and lubrication H Handlebar switches Dimmer switch Engine stop switch Fuel reserve switch Horn switch Start switch Turn signal switch Headlight bulb replacement Helmet holder High beam indicator light Horn switch Identification numbers record Indicator lights High beam indicator light Neutral indicator light Turn indicator light Inspecting the brake fluid level K Key identification number L Left view Loading and accessories Location of the important labels M Main switch Maintenance record Model label Modification Motorcycle noise regulation N Neutral indicator light P Parking Periodic maintenance Periodic maintenance chart for emission control system Pre operation check list Protective apparel R Rear brake pedal Rear brake pedal height and free play adjustment Rear shock absorber adjustment Recommended shift point Reporting safety defects Right view S Safe riding Shift pedal Sidestand Sidestand lubrication Sidestand clutch switch operation Spark plugs Specifications Speedometer Start switch Starter choke
44. ged or leaking oil seals every two years brake hoses every four years PERIODIC MAINTENANCE AND MINOR REPAIR EAU01541 Cable inspection and lubrication Damage to the outer housing of ca bles may allow internal rusting and cause interference with cable move ment Replace damaged cables as soon as possible to prevent unsafe conditions EWO00111 Lubricate the cables and cable ends If a cable does not operate smoothly ask a Yamaha dealer to replace it Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil 6 24 EAUO0773 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubricated since the grip must be re moved to get at the end of the throttle cable After removing the screws hold the end of the cable up in the air and put in several drops of lubricant With the throttle grip disassembled coat the metal surface of the grip assembly with a suitable all purpose grease PERIODIC MAINTENANCE AND MINOR REPAIR EAU00775 EAU00777 EAU01542 Brake and shift pedal Brake and clutch lever Sidestand lubrication lubrication lubrication Lubricate the sidestand pivoting point Lubricate the pivoting parts Lubricate the pivoting parts and metal to metal contact surfaces Check that the sidestand moves up Recommended lubricant Recommended lubricant and down smoothly Yamaha Chain and Cable Lube Yamaha Chain
45. hile it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 9 4 CONSUMER INFORMATION MAINTENANCE INTERVAL EAUO1059 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to document that maintenance has been completed in accordance with the emission warranty The chart below is printed only as a reminder to you that the maintenance work is required It is not acceptable proof of maintenance work DATE OF SERVICE MILEAGE 1 000km 600mi or 1 mo 7 000km 4 400 mi or 7 mos 13 000km 8 200 mi or 13 mos SERVICING DEALER NAME AND ADDRESS REMARKS 19 000km 12 000mi or 19 mos 25 000km 15 800mi or 25 mos 31 000km 19 600 mi or 31 mos 37 000km 23 400 37 mos CONSUMER INFORMATION _ _ MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE MILEAGE NAME AND ADDRESS REMARKS 43 000km 27 200mi or 43 mos 49 000km 81 000mi or
46. icinity of an open flame 2 Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your mo torcycle in an area that has adequate ventilation 3 Always turn off the engine before leaving the motorcycle unattended and remove the ignition key When parking the motorcycle note the following a The engine and exhaust system may be hot Park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas b Do not park the motorcycle on a slope or soft ground the motorcycle may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame The motorcycle could catch fire 1 5 N SAFETY INFORMATION 4 When transporting the motorcycle in another vehicle be sure it is kept upright and that the fuel cock is turned to ON or RES for vacuum type OFF for manual type If it should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get in your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it off with soap and water and change your clothes SAFETY INFORMATION EAUO0025 Location of the important labels Please read the following labels carefully before ope
47. ing preload adjusting ring 2 Position indicator EAU00300 Rear shock absorber adjustment Each shock absorber is equipped with a spring preload adjusting ring Adjust spring preload as follows Turn the ad justing ring in direction to increase spring preload and in direction to de crease spring preload Make sure that the appropriate notch in the adjusting ring is aligned with the position indica tor on the rear shock absorber ie Soft Standard Hard Adjusting 4 2 4 5 position 000040 A WARNING Always adjust each shock absorber to the same setting Uneven adjust ment can cause poor handling and loss of stability EAU00330 Sidestand This model is equipped with an ignition circuit cut off system The motorcycle must not be ridden when the sidestand is down The sidestand is located on the left side of the frame Refer to page 5 1 for an explanation of this sys tem This motorcycle must not be operat ed with the sidestand in the down position If the stand is not properly retracted it could contact the ground and distract the operator re sulting in a possible loss of control Yamaha has designed into this mo torcycle a lockout system to assist the operator in fulfilling the respon sibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction return the motorcycle to a Yamaha dealer immediately for
48. is clean towel or soft absorbent cloth Clean the seat with a vinyl uphol stery cleaner to keep the cover pli able and glossy Automotive type wax may be ap plied to all painted and chrome plated surfaces Avoid combina tion cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes CLEANING AND STORAGE EAU01026 B STORAGE Long term storage 60 days or more of your motorcycle will require some pre ventive procedures to guard against deterioration After thoroughly cleaning the motorcycle prepare for storage as follows 1 Fill the fuel tank with fuel and add fuel stabilizer if available 2 Remove the spark plugs pour about one tablespoon of engine oil in each spark plug hole and rein stall the spark plugs Turn the en gine over several times ground spark plug leads to coat the cylin der walls with oil When using the starter motor to crank the engine remove the spark plug wires and ground them to pre vent sparking EW000127 7 2 Lubricate all control cables 4 Block up the frame to raise both wheels off the ground 5 Tie a plastic bag over the exhaust pipe outlets to prevent moisture from entering 6 If storing in a humid or salt air at mosphere coat all exposed metal surfaces with a light film of oil Do not apply oil to any rubber parts or the seat cover 7 Remove the batter
49. lectrode gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion Spark plug gap 0 7 0 8 mm 0 028 0 031 in 2 Clean the gasket surface Wipe off any grime from the threads 3 Install the spark plug and tighten it to the specified torque Tightening torque Spark plug 20 Nm 2 0 m kg 14 ft lb NOTE e If a torque wrench is not available when you are installing a spark plug a good estimate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tightened to the specified torque as soon as possible 4 Install the spark plug caps the inder head covers and the screws 6 9 EMMISION HOSE ROUTING From fuel tank Carburetor Canister To atmosphere EAU00499 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before using this motorcycle be sure to check the fol lowing Check each hose connection Check each hose and canister for cracks or damage Replace if damaged e Make sure the canister breather is not blocked Clean it if necessary PERIODIC MAINTENANCE AND MINOR REPAIR 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 level settles before checking 1 Oil level window 3 The oil
50. level should be between 2 Maximum level mark the maximum and minimum marks If the level is low fill the en gine with sufficient oil to the speci fied level EAU00514 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 6 10 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 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Engine oil drain plug 1 Oil filter cover 3 Remove the drain plug and drain 279009 the oil 4 Remove the oil filter bolts oil filter and O ring 5 Reinstall the drain plug and tighten it to the specified torque Tightening torque Drain plug 43 Nm 4 3 m kg 31 40 6 Install the new oil filter new O ring and the filter cover Then tighten the oil filter bolts to the specified torque Tightening torque Oil filter bolts 10 Nm 1 0 m kg 7 2 ft lb 1 O ring 2 Oil filter element NOTE a Make sure the O ring is seated proper ly 7 Fill the engine with oil Install the oil filler cap and tighten it Recommended oil See page 8 1 Oil qu
51. ns or if trouble occurs in the throttle system Turn the switch to RUN to start the engine In case of emergency turn the switch to OFF to stop the engine EAU00149 Fuel reserve switch FUEL This switch should usually be kept while riding If you run out of fuel while riding move the switch to RES and refuel at the first opportunity Then move the switch to ON NOTE When the switch is turned to reserve RES about 2 5 L 0 5 Imp gal 0 7 US gal remain in the fuel tank EAU00141 Start switch START The starter motor cranks the engine when pushing the start switch 000005 starting the engine 3 3 1 Clutch lever EAU00152 Clutch lever The clutch lever is located on the left handlebar and the ignition circuit cut off system is incorporated in the clutch lever holder Pull the clutch lever to the handlebar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch oper ation Refer to the engine starting pro cedures for a description of the ignition circuit cut off system INSTRUMENT AND CONTROL FUNCTIONS 1 Shift pedal Shift pedal This motorcycle is equipped with a con stant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in com bination with the clutch when shifting EAU00157 1 Front brake lever
52. o replace the shoes PERIODIC MAINTENANCE AND MINOR REPAIR 1 Minimum level mark 000732 Inspecting the brake fluid level Insufficient brake fluid may let air enter the brake system possibly causing the brakes to become ineffective Before riding check that the brake fluid is above the minimum level and fill when necessary Observe these precautions e When checking the fluid level make sure the top of the master cylinder is level by turning the han dlebars e Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake perfor mance Recommended brake fluid DOT 4 NOTE If DOT 4 is not available DOT 3 can be used e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor brake performance Be careful that water does not en ter the master cylinder when refill ing Water will significantly lower the boiling point of the fluid and may result in vapor lock 6 23 e Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately e Have a Yamaha dealer check the cause if the brake fluid level goes down EAU00742 Brake fluid replacement The brake fluid should be replaced only by trained Yamaha service personnel Have the Yamaha dealer replace the following components during periodic maintenance or when they are dam a
53. off the main switch and the switch of the circuit in question Install a new fuse of the spec ified amperage Turn on the switches and check if the electrical device oper ates If the fuse immediately blows again consult a Yamaha dealer 000103 Do not use fuses of higher amper age rating than those recommend ed Substitution of a fuse of improper rating can cause extensive electrical system damage and pos sibly a fire Specified fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse 6 29 1 Screw x 2 Headlight bulb replacement 000107 It is advisable to have Yamaha dealer perform this removal and re assembly If the headlight bulb burns out replace the bulb as follows 1 Remove the screws holding the headlight unit PERIODIC MAINTENANCE AND MINOR REPAIR 5 Reinstall the bulb holder cover connector and headlight unit If the headlight beam adjustment is nec essary ask a Yamaha dealer to make that adjustment 1 Connector 1 Bulb holder 2 Bulb 3 Turn the bulb holder counterclock 2 Disconnect the connector and re wise to remove it and remove the move the bulb holder cover defective bulb Ewo00120 Keep flammable products and your hands away from the bulb while it is on as it is hot Do not touch the bulb until it cools down 4 Put a new bulb into position and secure it in place with the bulb holder 6 30 PERIODIC MAI
54. r using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN PERIODIC MAINTENANCE AND MINOR REPAIR 1 Maximum level mark 2 Minimum level mark Replenishing the battery fluid A poorly maintained battery will cor rode and discharge quickly The bat tery fluid should be checked at least once a month The level should be be tween the minimum level and maxi mum level marks Use only distilled water if refilling is necessary EC000100 Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water 6 28 Battery storage When the motorcycle will not be used for a month or longer re move the battery fully charge it and store it in a cool dry place Completely recharge the battery before reinstalling e if the battery will be stored for longer than two months check the specific gravity of the fluid at least once a month and recharge the battery when it is too low Always make sure the tions are correct when putting the battery back in the motorcycle Make sure the breather hose is properly connected and is not damaged or obstructed PERIODIC MAINTENANCE AND MINOR REPAIR Main fuse Headlight fuse Ignition fuse 1 2 3 Signaling system fuse 4 5 Spare fuse x 2 EAUO0818 Fuse replacement The fuse box is located under the rider seat If any fuse is blown turn
55. r if cracked or damaged 6 7 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Cylinder head cover 2 Screw x 2 EAU01486 Spark plugs Removal 1 Remove the rear right and front left cylinder head covers by re moving the screws 2 Remove the spark plug caps 1 Spark plug wrench 3 Use the spark plug wrench in the tool kit to remove the spark plugs as shown Inspection The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine Normally all spark plugs from the same engine should have the same color on the white insulator around the center elec trode The ideal color at this point is a medium to light tan color for a motor cycle that is being ridden normally if one spark plug shows a distinctly differ 6 8 ent color there could be something wrong with the engine Do not attempt to diagnose such problems yourself In stead take the motorcycle to a Yamaha dealer You should periodical ly remove and inspect the spark plugs because heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion be comes excessive or if carbon and oth er deposits are excessive you should replace the spark plug with the speci fied plug Specified spark plug BP7ES NGK or W22EP U DENSO PERIODIC MAINTENANCE AND MINOR REPAIR F a Spark plug gap Installation 1 Measure the e
56. rance when engine is cold y Y Y Y Y Check condition Adjust gap and clean Spark plug Replace at 13 000 km 8 200 mi Replace Replace or 13 months and thereafter every 12 000 km 7 600 mi or 12 months Valve clearance Crankcase ventilation Check ventilation hose for cracks or damage 4 4 4 4 system Replace if necessary Y Check fuel hose and vacuum pipe for cracks Fuel line or damage Replace if necessary Check for leakage Exhaust system Retighten if necessary Replace gasket s if necessary 4 Carburetor Synchronization Adjust synchronization of carburetors Check and adjust engine idle speed Adjust cable free play Evaporative emission Check control system for damage control system Replace if necessary Idle speed Since these items require special tools data and technical skills they should be serviced by a Yamaha dealer California only 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE For farther odometer reading beyond those listed repeat the above maintenance at the period established 1 Every 6 000 km 3 800 mi and 2 Every 12 000 km 7 600 mi and 3 Every 24 000 km 15 200 mi intervals 6 4 PERIODIC MAINTENANCE AND MINOR REPAIR EAUO0472 GENERAL MAINTENANCE AND LUBRICATION CHART ROUTINE INITIAL ODOMETER READINGS 1 000 km 600 mi or 1 month
57. rating this motorcycle AWARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 3 2118 0 CAUTION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint If electrolyte spills wash area with fresh water immediately Be sure to connect breather hose after installing battery 3JL 28177 A0 N SAFETY INFORMATION 3 California only EMISSION HOSE ROUTING FROM FUEL TANK CANISTER TO ATMOSPHERE 4YN 21686 00 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 200kPa 2 00kgf cm 29psi REAR 225kPa 2 25kgf cm 33psi 90 kg 198 105 maximum load FRONT 200kPa 2 00kgf cm 29psi REAR 250kPa 2 50kgf cm 36psi 5FB 21668 00 Left view 2511 Righi view esses DEP Controls Instruments RR 5 059 DESCRIPTION EAUO0026 Left view 1 Headlight 2 Air filter 3 Rider seat 4 Tool kit 5 Passenger seat page 6 29 page 6 13 page 3 8 page 6 1 page 3 7 2 1 6 Rear shock absorber spring preload adjusting ring 7 Main switch 8 Starter choke NJ 9 Shift pedal page 3 9 page 3 1 page 3 6 page 3 4 D
58. record Key identification number Vehicle identification number Model label Reporting safety defects Motorcycle noise regulation Maintenance record Street and enduro motorcycle limited warranty Yamaha extended service CONSUMER INFORMATION EAU01039 EAU01040 Identification numbers record Record the key identification number vehicle identification number and mod el label information in the spaces pro vided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is sto len 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER 3 MODEL LABEL INFORMATION 1 Key identification number EAU01042 Key identification number The key identification number is stamped on the key Record this num ber in the space provided and use it for reference when obtaining a new key 9 1 1 Vehicle identification number EAUO1043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your state CONSUMER INFORMATION 1 Model label EAU01050 Model label The model label is affixed to the frame under the seat See page 3 7 for seat removal procedures Record the infor mation on this label in
59. rfac es or plastic parts EAUO0189 Recommended fuel UNLEADED FUEL Fuel tank capacity Total 13 5 L 3 0 Imp gal 3 6 US gal Reserve 2 5 L 0 5 Imp gal 0 7 US gal Your Yamaha engine has been de Signed to use regular unleaded gaso line with a pump octane number 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a dif ferent brand of gasoline or premium unleaded fuel Unleaded fuel will give you longer spark plug life and reduced maintenance cost If unleaded gasoline is not available then leaded regular gasoline can be used Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol con taining methanol is not recommended by Yamaha because it can cause fuel system damage or vehicle mance problems 1 Starter choke EAUO0210 Starter choke Starting a cold engine requires a richer air fuel mixture A separate starter cir cuit supplies this mixture Move in direction to turn on the starter choke Move in direction to turn off the starter choke INSTRUMENT AND CONTROL FUNCTIONS 1 Steering lock EAU01499 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 t
60. rovide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts orthe drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs e addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S
61. rving contain anti friction additives which will cause clutch and or starter clutch slippage resulting in reduced component life and poor engine performance Quantity Periodic oil change 2 6 L 2 3 Imp qt 2 8 US qt 2 8 L 2 5 Imp qt 3 0 US qt 3 2 L 2 8 Imp qt 3 4 US qt With oil filter replacement Total amount Final gear oil Type Final gear case capacity Air filter Fuel Type Fuel tank capacity Reserve amount Carburetor Type x quantity Manufacturer Spark plug Type Manufacturer Gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation SAE 80 API GL 4 hypoid gear oil 0 19 L 0 7 Imp qt 0 20 US qt Dry type element Regular gasoline 13 5 L 3 0 Imp gat 3 6 US gal 2 5 L 0 5 Imp gal 0 7 US gal BDS34 x2 MIKUNI BP7ES NGK or W22EP U DENSO 0 7 0 8 mm 0 028 0 031 in Wet multiple disc Spur gear 1 944 Shaft drive 3 071 Constant mesh 5 speed Left foot operation Gear ratio 1st 2nd 3rd 4th 5th Chassis Frame type Caster angle Trail Tire Type Size Front Rear Manufacturer model Front Rear Maximum load SPECIFICATIONS 2 714 1 900 1 458 1 167 0 967 Pressed backbone 31 5 125 mm 4 92 in With tube 3 00 19 49S 140 90 15M C 70S Bridgestone L303A Dunlop F14G Bridgestone G508 Dunlop K425 220 kg 485 Ib XV535
62. s Manual that failure may not be covered under warranty advise us of your new address by sending a postcard listing your motorcycle Q What responsibility does my dealer have under this warranty model name V I N frame number dealer number dealer s name as it A Each Yamaha Motorcycle dealer is expected to is shown on your warranty card your name and new mailing address Mail to 1 Completely set up every new machine before sale YAMAHA MOTOR CORPORATION U S A 2 Explain the operation maintenance and warranty requirements to your satis P O Box 6555 faction at the time of sale and upon your request at any later date California 90630 p 4 ypress California 3 Each Yamaha Motorcycle dealer is held responsible for his setup service and Attention Warranty Department warranty repair work This will ensure that Yamaha Motor Corporation U S A has an up to date Q Is the warranty transferable to second owners Yes remainder of the existing warranty can be transferred upon request The registration record in accordance with federal law unit has to be inspected and re registered by an authorized Yamaha Motorcycle dealer for the policy to remain effective 9 8 CONSUMER INFORMATION YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e Y E S is designed and administered by Yamaha Motor Corporation to p
63. s within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty ENGINE DISPLACEMENT 50cc to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 280cc or over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR COR PORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY IN CIDENTAL OR CONSEQUENTIAL DAMAGES INCLUD ING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 EAUO1061 CONSUMER INFORMATION _
64. se the trip odometer to estimate how far you can ride on a tank of fuel This information will enable you to plan fuel stops in the future INSTRUMENT AND CONTROL FUNCTIONS 1 Dimmer switch LIGHTS 2 Turn signal switch TURN 3 Horn switch HORN EAUO0118 Handlebar switches EAU00122 Dimmer switch LIGHTS Turn the switch to HI for the high beam and to LO for the low beam EAUO1189 Turn signal switch TURN This model is equipped with self can celing turn signals To signal a right hand turn push the switch to the right To signal a left hand tum push the switch to the left Once the switch is re leased it will return to the center posi tion self cancel after the motorcycle has traveled both about 150 m 490 ft and for approximately 15 seconds The self canceling mech anism only operates when the motor cycle is moving Therefore the signal will not self cancel while you are stopped at an intersection The signal may also be canceled manually by pushing the switch in after it has re turned to the center position EAU00130 Horn switch HORN Press the switch to sound the horn INSTRUMENT AND CONTROL FUNCTIONS 1 Engine stop switch ENGINE STOP 2 Fuel reserve switch FUEL 3 Start switch START EAU00137 Engine stop switch ENGINE STOP The engine stop switch is a safety de vice for use in an emergency such as when the motorcycle overtur
65. switch controls the ignition and lighting systems Its operation is described below EAU00032 ON All electrical circuits are switched on and the headlight meter light taillight and front position lights come on The engine can be started The key cannot be removed in this position EAU00038 OFF All electrical circuits are switched off The key can be removed in this posi tion 1 Push 2 Release 3 Turn EAU00052 P Parking The taillight and front position light come on but all other circuits are off With the key at OFF push it into the main switch and release it Then turn it counterclockwise to P and remove it To cancel the parking turn the key clockwise 3 1 EAU00027 1 High beam indicator light HIGH BEAM 2 Neutral indicator light NEUTRAL 3 Tum indicator light TURN EAUO00056 Indicator lights EAUO0064 High beam indicator light HIGH BEAM This indicator comes on when the headlight high beam is used EAU00062 Neutral indicator light NEUTRAL This indicator comes on when the transmission is in neutral 000059 Turn indicator light TURN This indicator flashes when the turn switch is moved to the left or right 1 Reset knob 2 Odometer 3 Trip odometer EAU00095 Speedometer The speedometer shows riding speed This speedometer is equipped with an odometer and trip odometer The trip odometer can be reset to 0 with the reset knob U
66. t 2 Locknut c Free play EAUO0696 Front brake lever free play adjustment The free play at the front brake lever should be 2 5 mm 0 08 0 20 in 1 2 Loosen the locknut Turn the adjusting bolt in direction 8 to increase free play or in direc tion to decrease free play After adjusting tighten the locknut 6 20 000099 Check the brake lever free play Be sure the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the brake sys tem This air must be removed by bleeding the brake system before the motorcycle is operat ed Air in the system will cause greatly diminished braking ca pability and can result in loss of control and an accident Have a Yamaha dealer inspect and bleed the system if necessary PERIODIC MAINTENANCE AND MINOR REPAIR 1 Footrest c Pedal height d Free play EAUO0711 Rear brake pedal height and free play adjustment It is advisable to have a Yamaha dealer make this adjustment 000104 brake pedal height should be ad justed before adjusting the brake pedal free play Pedal height The brake pedal should be positioned approximately 38 mm 1 5 in above the top of the footrest 1 Adjusting bolt 2 Locknut 1 Loosen the locknut 2 Turn the adjusting bolt in direction to raise pedal height or in direc tion to lower pedal height 3 Tighten the locknut Aft
67. t it cool for 5 to 10 minutes after every hour of opera tion Vary the speed of the motorcycle from time to time Do not operate it at one set throttle position 150 500 km 90 300 mi Avoid prolonged operation above 1 2 throttle Rev the motorcycle freely through the gears but do not use full throttle at any time 500 1 000 km 300 600 mi Avoid cruising speeds in excess of 3 4 throttle 000056 After 1 000 km 600 of operation be sure to replace the engine oil oil filter and final gear oil 5 6 1 000 km 600 mi and beyond Avoid prolonged full throttle operation Vary speed occasionally 000049 If any engine trouble should occur during the break in period consult a Yamaha dealer immediately OPERATION AND IMPORTANT RIDING POINTS EAU00460 Parking When parking the motorcycle stop the engine and remove the ignition key 000058 A WARNING The exhaust system is hot Park the motorcycle in a place where pedes trians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may over turn 5 7 Periodic maintenance 6 1 Periodic maintenance chart for emission control System epar teta nias 6 3 General maintenance and lubrication chart 6 5 Spark Plugs ec DE 6 8 Canister for California
68. the time involved The engine exhaust pipes and mufflers will be very hot after the engine has been run Be careful not to touch them or to allow any clothing item to contact them during inspection or repair e If any item in the PRE OPERATION CHECK is not working properly have it inspected and repaired before op IN erating the motorcycle 4 2 i ANT RIDING POINTS 7 ee oS OPERATION AND IMPORTANT RIDING POINTS EAUO0372 EAU00373 A WARNING e Before 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 Never 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 Before 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 EAU00376 Be careful where you store per sonal items on the motorcycle Avoid blocking the air cleaner intake or performance will suf fer Be careful not to put anything near the battery and its termi nals Electrical failure and acid corrosion may result EAU00387 Starting and warming up a cold engine NOTE
69. uel Go to compression check in the fuel tank 2 Compression Use the electric starter 1 No compression em H There is compression Supply fuel HH Engine doesn t start go to compression check Go to ignition check Ask Yamaha to inspect 3 Ignition Wet L Remove spark Wipe clean with dry cloth and correct spark gap or replace spark plugs Open throttle haif way and start plugs and the engine check electrodes Dry Ask a Yamaha dealer to inspect Engine doesn t start go to battery check 4 Battery Engine turns over Quickly Battery good Use the electric starter Engine turns over slowly Check connections or recharge E 6 32 Engine doesn t start ask a Yamaha dealer to inspect CLEANING AND STORAGE CLEANING AND STORAGE ee 2 ee eee EAU01330 A CLEANING Frequent thorough cleaning of your motorcycle will not only enhance its ap pearance but will improve its general performance and extend the useful life of many components 00002 e Improper cleaning can damage the cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic e Do not use any harsh chemical products on plastic parts Be
70. way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or obscure lights or reflectors a Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum 14 SAFETY INFORMATION b Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects Wind may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when being passed by or passing large vehi cle Certain accessories can displace the operator from his or her normal riding position This improper position limits the freedom of movement of the operator and may limit control ability Therefore such accessories are not recommended 2 Caution must be used if adding electrical accessories If these accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn off the engine when refueling b Take care not to spill any gasoline on the engine or exhaust system when refueling c Never refuel while smoking or in the v
71. y and fully charge it Store it in a cool dry place and completely recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F or more than 30 C 90 F See page 6 28 for battery storage precau tions NOTE Make any necessary repairs before storing the motorcycle SPECIFICATIONS EAUO1038 Specifications Model Dimensions Overall length Overall width Overall height Seat hight Wheelbase Ground clearance Minimum turning radius Basic weight with oil and full fuel tank Engine Engine type Cylinder arrangement Displacement Bore x Stroke Compression ratio Starting system Lubrication system XV535 XV535C 2 225 mm 87 6 in 780 mm 30 7 in 1 120 mm 44 1 in 720 mm 28 3 in 1 520 mm 59 8 in 160 mm 6 3 in 2 900 mm 114 2 in 195 kg 430 Ib XV535 196 kg 432 Ib XV535C Air cooled 4 stroke SOHC V type 2 cylinder 535 cm 76 0 x 59 0 mm 2 99 x 2 32 in 9 1 Electric starter Wet sump Engine oil 0 10 30 50 70 90 110 130 Edo qud dl at YAMALUBE 4 10W30 or SAE 10W30 i YAMALUBE 4 20W40 i or SAE 20W40 20 10 0 10 20 30 40 50 C Recommended engine oil classification API Service SE SF SG type or higher Be sure to use motor oils that do not contain anti fric tion modifiers Passenger car motor oils often labeled Energy Conse

Yamaha 1999 Virago 535 Owner's Manual

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