Yamaha Virago XV535 Owner'S Manual Download Page 55

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

EAU00694

Adjusting the clutch lever free
play

The clutch lever free play should mea-
sure 10–15 mm as shown. Periodically
check the clutch lever free play and, if
necessary, adjust it as follows.

1. Loosen the locknut at the clutch

lever.

2. To increase the clutch lever free

play, turn the adjusting bolt in di-
rection

. To decrease the clutch

lever free play, turn the adjusting
bolt in direction

3. If the specified clutch lever free

play could be obtained as de-
scribed above, tighten the locknut
and skip the rest of the procedure,
otherwise proceed as follows.

4. Fully turn the adjusting bolt at the

clutch lever in direction

to loos-

en the clutch cable.

5. Loosen the locknut at the crank-

case.

6. To increase the clutch lever free

play, turn the adjusting nut in di-
rection

. To decrease the clutch

lever free play, turn the adjusting
nut in direction

7. Tighten the locknut at the clutch

lever and the crankcase.

1. Locknut
2. Clutch lever free play adjusting bolt
c. Clutch lever free play

1. Locknut
2. Clutch lever free play adjusting nut

E_3bt.book Page 18 Thursday, September 7, 2000 10:01 AM

Summary of Contents for Virago XV535

Page 1: ...3BT 28199 E7 OWNER S MANUAL XV535 ...

Page 2: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 3: ...o enjoy all advantages of your XV535 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer...

Page 4: ...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 Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informati...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_3bt book Page 2 Thursday September 7 2000 10 01 AM ...

Page 6: ...UAL 2000 by Yamaha Motor Co Ltd 1st Edition July 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_3bt book Page 3 Thursday September 7 2000 10 01 AM ...

Page 7: ...NT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 8: ...E_3bt book Page 2 Thursday September 7 2000 10 01 AM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 10: ...even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however should...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 12: ...11 3 Rider seat page 3 8 4 Owner s tool kit page 6 1 5 Helmet holder page 3 9 6 Passenger seat page 3 7 7 Shock absorber spring preload adjusting ring page 3 9 8 Main switch page 3 1 9 Starter choke lever page 3 6 10 Shift pedal page 3 4 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 13: ...Right view 11 Rear turn signal light page 6 33 12 Fuel sub tank 13 Fuel tank page 3 5 14 Front turn signal light page 6 33 15 Brake pedal page 3 4 16 Battery page 6 29 E_3bt book Page 2 Thursday September 7 2000 10 01 AM ...

Page 14: ...struments 1 Clutch lever page 3 3 2 Speedometer unit page 3 2 3 Brake lever page 3 4 4 Throttle grip page 6 14 5 Right handlebar switches page 3 3 6 Left handlebar switches page 3 2 E_3bt book Page 3 Thursday September 7 2000 10 01 AM ...

Page 15: ...3 2 Clutch lever 3 3 Shift pedal 3 4 Brake lever 3 4 Brake pedal 3 4 Fuel tank cap 3 5 Fuel 3 5 Starter choke lever 3 6 Steering lock 3 7 Seats 3 7 Helmet holder 3 9 Adjusting the shock absorber assemblies 3 9 Sidestand 3 10 Ignition circuit cut off system 3 10 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 16: ...hed in and then released before it can be turned to P ECA00043 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge EAU00056 Indicator lights EAU00063 High beam indicator light This indicator light comes on when the high beam of the headlight is switched on EAU00061 Neutral indicator light This indicator light comes on when the transmission is...

Page 17: ...ch To signal a right hand turn push this switch to the right To signal a left hand turn push this switch to the left When released the switch returns to the cen ter position Since this model is equipped with a self canceling system the turn signal lights will self cancel after the motorcycle has traveled both about 150 m and for ap proximately 15 seconds However the turn signal lights can also be ...

Page 18: ...n the ON position If you run out of fuel while riding set the switch to RES refuel as soon as pos sible and then set the switch back to ON NOTE After switching to RES approximately 2 5 L of fuel remain in the fuel tank EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever...

Page 19: ...nt mesh transmission equipped on this motorcycle EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal E_3bt book Page 4 Thursday September...

Page 20: ... cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked _ EWA00025 WARNING _ Make sure that the fuel tank cap is properly closed before riding _ EAU01183 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown in the illustra tion EW000130 WARNING Do not overfil...

Page 21: ...tane grade EAU02976 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke Recommended fuel Regular unleaded gasoline with a research octane number of 91 or higher Fuel tank capacity Total amount 13 5 L Reserve amount 2...

Page 22: ...that the steering is locked remove the key and then close the lock cover To unlock the steering 1 Open the steering lock cover and then insert the key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover EAU02940 Seats Passenger seat To remove the passenger seat 1 Insert the key into the seat lock and then turn ...

Page 23: ... the rider seat 1 Remove the passenger seat 2 Remove the bolts and then pull the rider seat off To install the rider seat 1 Insert the projections on the front of the rider seat into the seat hold ers as shown place the seat in the original position and then tighten the bolts 2 Install the passenger seat NOTE Make sure that the seats are properly secured before riding 1 Projection 2 Seat holder 1 ...

Page 24: ...echanism beyond the maximum or minimum settings EW000040 WARNING Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Adjust the spring preload as follows To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a To de crease the spring preload and thereby soften ...

Page 25: ...ling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly EAU03720 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the tr...

Page 26: ... clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should...

Page 27: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 28: ...el in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 7 Final gear oil Check vehicle for oil leakage 6 9 6 10 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for...

Page 29: ...y 6 15 6 17 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 25 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 25 Sidestand Make sure that operation is smooth Lubricate pivot if necessary 6 25 6 26 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tight...

Page 30: ...E_3bt book Page 3 Thursday September 7 2000 10 01 AM ...

Page 31: ... Starting a cold engine 5 1 Starting a warm engine 5 2 Shifting 5 3 Recommended shift points for Switzerland only 5 3 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 32: ...t The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 11 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to 2 Shift the tr...

Page 33: ...ngine is cold 6 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm E_3bt book Page 2 Thursday September 7 2000 10 01 AM ...

Page 34: ... motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU02941 Recommended shift points for Switzerland only The recommended shift ...

Page 35: ... ma terial carefully Since the engine is brand new do not put an excessive load on it for the first 1 000 km The various parts in the en gine wear and polish themselves to the correct operating clearances During this period prolonged full throttle oper ation or any condition that might result in engine overheating must be avoided EAU00444 0 150 km Avoid prolonged operation above 1 3 throttle After...

Page 36: ...mmediately have a Yamaha dealer check the vehicle EAU00460 Parking When parking stop the engine and then remove the key from the main switch EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the motorcycle may overturn E_3bt book Page 5 Thursday Sept...

Page 37: ...he front brake pads and rear brake shoes 6 21 Checking the brake fluid level 6 22 Changing the brake fluid 6 23 Checking and lubricating the cables 6 23 Checking and lubricating the throttle grip and cable 6 24 Checking and lubricating the brake and shift pedals 6 25 Checking and lubricating the brake and clutch levers 6 25 Checking and lubricating the sidestand 6 25 Lubricating the rear suspensio...

Page 38: ...tor 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...

Page 39: ...L CHECK 1 10 20 30 40 1 Fuel line Check fuel hoses and vacuum hose for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust 5 Air filter element Clean Replace 6 Battery Check electrolyte level and specific gravity Make sure that the breather hose is properly routed 7 Clutch Check operation Adjust 8 Front brake Ch...

Page 40: ...arings Check bearing play and steering for roughness Lubricate with lithium soap based grease Every 20 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assemblies Check operation and shock absorbers for oil le...

Page 41: ...e brake master cylinder and caliper and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 24 Final gear oil Check oil level and vehicle for oil leakage Change 25 Front and rear brake switches Check operation 26 Moving parts and cables Lubricate 27 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER READ...

Page 42: ...hown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the motorcycle is ridden normally 2 Check that all spark plugs installed in the engine have the same color NOTE If any spark plug shows a distinctly dif ferent color the engine co...

Page 43: ...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...

Page 44: ...ngine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom left side of the crank case NOTE The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the corre...

Page 45: ...il 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 element Tightening torque Oil filter element cover bolt 10 Nm 1 0 m kg E_3bt book Page 8 Thursday September 7...

Page 46: ... 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...

Page 47: ...nge 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 a...

Page 48: ... the fuel tank to po sition it away from the air filter case Do not remove the fuel tank EW000071 WARNING _ Make sure that the fuel tank is well supported Do not tilt or pull the fuel tank too much otherwise the fuel hoses may come loose which could cause fuel leakage _ 4 Remove the air filter case cover screw 5 Slide the air filter case cover so as to unhook the tab on the rear of the cover from ...

Page 49: ...d without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn _ 9 Place the air filter case cover in the original position and then install the screw 10 Install the fuel tank by installing the bolts EW000131 WARNING _ Make sure that the fuel hoses and vacuum hose are properly connect ed and routed and not pinched Re place any damaged hoses _ EC000...

Page 50: ...d must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart NOTE A diagnostic tachometer is needed to make this adjustment 1 Attach the tachometer to the spark plug lead 2 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally rev ving it to 4 000 5 000 r min NOTE The engine is warm when it...

Page 51: ... necessary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart a Throttle cable free play E_3bt book Page 14 Thursday Sept...

Page 52: ...performance and safety characteris tics of your motorcycle you should keep the following precautions in mind NEVER OVERLOAD THE MOTORCYCLE Operation of an overloaded motorcycle may result in tire damage loss of control or severe injury Make sure that the total weight of rid er passenger cargo and ac cessories does not exceed the specified maximum load for the vehicle Do not carry along loosely pac...

Page 53: ... 08E NOTE The tire tread depth limits may differ from country to country Always comply with the local regulations EW000079 WARNING Have a Yamaha dealer replace excessively worn tires Besides being illegal operating the motorcycle with excessively worn tires decreases riding sta bility and can lead to loss of control The replacement of all wheel and brake related parts includ ing the tires should b...

Page 54: ...ce it as soon as possible with a high quality product EAU00685 Spoke wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends or warpage and the spokes for looseness or dam age before each ride If any dam age is found have a Yamaha dealer replace the wheel Do not ...

Page 55: ...ever free play could be obtained as de scribed above tighten the locknut and skip the rest of the procedure otherwise proceed as follows 4 Fully turn the adjusting bolt at the clutch lever in direction a to loos en the clutch cable 5 Loosen the locknut at the crank case 6 To increase the clutch lever free play turn the adjusting nut in di rection a To decrease the clutch lever free play turn the a...

Page 56: ...make sure that the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU00711 Adjusting the ...

Page 57: ...ING After adjusting the brake pedal height the brake pedal free play must be adjusted Brake pedal free play The brake pedal free play should mea sure 20 30 mm at the brake pedal end Periodically check the brake pedal free play and if necessary adjust it as follows To increase the brake pedal free play turn the adjusting nut at the brake rod in direction a To decrease the brake pedal free play turn...

Page 58: ...hecking the front brake pads and rear brake shoes The front brake pads and the rear brake shoes must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart EAU01119 Front brake pads Each front brake pad is provided with wear indicator grooves which allow you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear ch...

Page 59: ...rn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage Observe these precautions When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braki...

Page 60: ...well as the brake hose replaced at the intervals listed below or whenever it is damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is dam...

Page 61: ...ays be lubricated at the same time 1 Remove the throttle grip by remov ing the screws 2 Disconnect the throttle cable hold it up and then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throt tle grip housing 4 Grease the metal to metal contact surface of the throttle grip and then install the grip by...

Page 62: ...e each ride and the lever pivots should be lu bricated if necessary EAU03165 Checking and lubricating the sidestand The operation of the sidestand should be checked before each ride and the sidestand pivot and metal to metal contact surfaces should be lubricated if necessary EW000113 WARNING If the sidestand does not move up and down smoothly have a Yamaha dealer check or repair it Recommended lub...

Page 63: ...g points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Molybdenum disulfide grease E_3bt book Page 26 Thursday September 7 2000 10 01 AM ...

Page 64: ...n 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be che...

Page 65: ...a dealer check or repair the steering EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings E_3bt book Page 28 Thursday September 7 2000 10 01 AM ...

Page 66: ...ow the minimum level mark add distilled water to raise it to the maximum level mark EW000116 WARNING Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID EXTERNAL Flush with plenty of water INTERNAL...

Page 67: ...ully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever necessary 3 Fully charge the battery before installation 4 After installation make sure that the battery leads are properly con nected to the battery terminals and that the breather ho...

Page 68: ...amage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU03003 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the ...

Page 69: ...he bulb holder EC000105 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the bulb cover and then connect the coupler 6 Install...

Page 70: ... not equipped with a centerstand follow these precautions when removing the front and rear wheel or performing other mainte nance requiring the motorcycle to stand upright Check that the motor cycle is in a stable and level position before starting any maintenance A strong wooden box can be placed un der the engine for added stability To service the front wheel 1 Stabilize the rear of the motorcyc...

Page 71: ...e the wheel Securely support the motor cycle so that there is no danger of it falling over _ 1 Disconnect the speedometer ca ble from the front wheel 2 Loosen the front wheel axle pinch bolt then the wheel axle 3 Lift the front wheel off the ground according to the procedure on page 6 33 4 Pull the wheel axle out and then remove the wheel ECA00048 CAUTION _ Do not apply the brake after the wheel h...

Page 72: ...rd 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 _ It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that t...

Page 73: ...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...

Page 74: ...00103 WARNING _ After adjusting the brake pedal free play check the operation of the brake light _ EAU01008 Troubleshooting Although 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 rep...

Page 75: ... spark plugs and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Check the battery Open throttle halfway and operate the electric starter Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slowly The battery is good Ch...

Page 76: ...E_3bt book Page 39 Thursday September 7 2000 10 01 AM ...

Page 77: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 78: ...ll as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especially on s...

Page 79: ... shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding...

Page 80: ...inted surfaces 7 Let the motorcycle dry completely before storing or covering it EWA00031 WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor neri...

Page 81: ...ent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore...

Page 82: ...very month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery se...

Page 83: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 84: ...1 Starting system Electric starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG type or higher Quantity Without oil filter element replacement 2 6 L With oil filter element replacement 2 8 L Total amount dry engine 3 2 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do...

Page 85: ...t multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 944 Secondary reduction system Shaft drive Secondary reduction ratio 3 071 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 714 2nd 1 900 3rd 1 458 4th 1 167 5th 0 967 Chassis Frame type Pressed backbone Caster angle 31 5 Trail 125 mm Tires Front Type Tube tire Size 3 00 19 49S Man...

Page 86: ...pe Spoke wheel Size 15 M C MT 3 00 Brakes Front Type Single disc brake Operation Right hand Fluid DOT 4 or DOT 3 Rear Type Drum brake Operation Right foot Suspension Front Telescopic fork Rear Swingarm Springs shock absorbers Front Coil spring oil damper Rear Coil spring oil damper Wheel travel Front 150 mm Rear 85 mm Electrical system Ignition system T C I digital Charging system Type A C magneto...

Page 87: ... 5 21 W 2 Front turn signal light 12 V 21 W 2 Rear turn signal light 12 V 21 W 2 Meter lighting 14 V 3 W 1 Neutral indicator light 14 V 3 W 1 High beam indicator light 12 V 1 7 W 1 Turn signal indicator light 14 V 3 W 1 Fuses Main fuse 30 A Ignition fuse 15 A Signaling system fuse 15 A Headlight fuse 15 A E_3bt book Page 4 Thursday September 7 2000 10 01 AM ...

Page 88: ...tric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55 ...

Page 89: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_3bt book Page 1 Thursday September 7 2000 10 01 AM ...

Page 90: ...01E EAU01042 Key identification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space provided NOTE The vehicle identification number is used to identify your...

Page 91: ...e under the rider seat See page 3 7 for seat removal and installation proce dures Record the information on this label in the space provided This infor mation will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_3bt book Page 2 Thursday September 7 2000 10 01 AM ...

Page 92: ...ont fork checking 6 27 Fuel 3 5 Fuel consumption tips for reducing 5 4 Fuel reserve switch 3 3 Fuel tank cap 3 5 Fuses replacing 6 31 H Handlebar switches 3 2 Headlight bulb replacing 6 31 Helmet holder 3 9 High beam indicator light 3 1 Horn switch 3 2 I Identification numbers 9 1 Idling speed adjusting 6 13 Ignition circuit cut off system 3 10 Indicator lights 3 1 K Key identification number 9 1 ...

Page 93: ...lay adjusting 6 14 Throttle grip and cable checking and lubricating 6 24 Tires 6 15 Tool kit 6 1 Troubleshooting 6 37 Troubleshooting chart 6 38 Turn signal indicator light 3 1 Turn signal or tail brake light bulb replacing 6 33 Turn signal switch 3 2 V Valve clearance adjusting 6 14 Vehicle identification number 9 1 W Wheel bearings checking 6 28 Wheel front 6 34 Installing 6 35 Removing 6 34 Whe...

Page 94: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 95: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 96: ...PRINTED IN JAPAN 2000 7 0 2 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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