Table Of Contents - Yamaha XV 535 DX Virago Service Manual

Table of Contents

General Information1
Parts Replacement1
Engine Serial Numbers2
General Specifications2
Emergency Troubleshooting4
Engine Starting/Performance5
Ignition System5
Periodic Lubrication, Maintenance And Tune-Up6
Routine Checks6
Engine Oil Level6
Tire Pressure6
Maintenance Intervals7
Tires And Wheels7
Battery7
Removal/Installation And Electrolyte Level Check7
New Battery Installation9
Periodic Lubrication10
Engine Oil Level Check10
Engine Oil And Filter Change10
Front Fork Oil Change12
Periodic Maintenance13
Front Disc Brake13
Disc Brake Fluid Level13
Disc Brake Pad Wear14
Front Brake Lever Adjustment14
Rear Brake Pedal Height Adjustment15
Gearshift Pedal Adjustment15
Clutch Adjustment15
Throttle Operation/Adjustment16
Air Cleaner Removal/Installation17
Front/Rear Suspension Check18
Tune-Up19
Tools20
Air Cleaner Element20
Valve Adjustment20
Tdc For Rear/Front Cylinder22
Firing Range For Rear Cylinder22
Correct Spark Plug Heat Range23
Ignition Timing24
Carburetor Synchronization25
Carburetor Idle Speed Adjustment25
Maintenance Schedule25
Tire Inflation Pressure (Cold)26
Recommended Lubricants26
Approximate Refill Capacities27
Tune Up Specifications27
Engine Principles28
Servicing Engine In Frame28
Stroke Principles29
Engine Removal/Installation30
Cylinder Heads And Camshaft Removal34
Camshaft Inspection39
Cylinder Head Inspection40
Cylinder Head Installation41
Valves And Valve Components Removal/Assembly45
Valves And Valve Components Inspection46
Valves And Valve Components Installation47
Valve Spring Height47
Rocker Arm Assemblies48
Valve Guide Replacement48
Valve Seat Reconditioning48
Valve Lapping48
Rocker Arm Removal/Inspection/Installation49
Cylinder Removal/Inspection50
Cylinder Installation51
Piston Removal/Installation52
Piston Inspection53
Piston Clearance Measurement54
Piston Ring Removal/Installation55
Oil Pump Removal/Installation56
Oil Pump Disassembly/Inspection/Assembly57
Oil Strainer Removal/Inspection/Installation59
Primary Drive Gear Removal/Installation60
Camshaft Drive Chain And Damper62
Front/Rear Cylinder Removal/Installation62
Crankcase Disassembly63
Front/Rear Cylinder Inspection63
Crankcase Inspection64
Crankcase Bearings Inspection/Replacement64
Crankcase Bearings Assembly66
Crankshaft And Connecting Rods Removal/Installation67
Connecting Rod Inspection68
Connecting Rod Bearing And Oil Clearance Measurement68
Connecting Rod Side Clearance Measurement70
Crankshaft Inspection70
Crankshaft Bearing And Oil Clearance Measurement70
Middle Drive Gear Removal/Installation71
Starter Clutch And Reduction Gears Removal/Installatin73
Middle Drive Gear Inspection73
Break-In74
Starter Clutch And Reduction Gears Inspection74
500-Mile Service75
Engine Specifications75
Engine Tightening Torque77
Clutch Removal78
Clutch Parts List79
Clutch Inspection81
Clutch Installation84
Clutch Mechanism Free Play Adjustment86
Clutch Cable Replacement87
Shift Mechanism87
Shifter Assembly88
Shifter Removal/Inspection/Installation89
Transmission Removal/Installation91
Transmission Parts List91
Main Shaft Disassembly/Assembly92
Drive Axle Disassembly/Assembly94
Drive Axle Inspection95
Shift Drum And Forks Removal/Installation97
Shift Drum And Forks Inspection99
Clutch Specifications99
Clutch Tightening Torque99
Fuel, Emission Control And Exhaust Systems100
Carburetor Removal/Installation100
Carburetor Assembly Separation/Reassembly103
Carburetor Exploded View104
Individual Carburetor Disassembly/Assembly105
Individual Carburetor Cleaning And Inspection108
Carburetor Adjustments110
Coasting Enricher System110
Fuel Level Measurement110
Fuel Level Inspection/Adjustment111
Throttle Cable Replacement112
Throttle Cable Installation113
Fuel Shutoff Valve Troubleshooting/Removal/Installation113
Fuel Filter Removal/Installation114
Fuel Pump Removal/Installation114
Shutoff Valve Parts List114
Fuel Tanks115
Sub-Fuel Tank115
Main Fuel Tank Removal/Installation116
Crankcase Breather System117
Evaporate Emission Control Parts Replacement117
Evaporate Emission Control Inspection/Replacement117
Roll-Over Valve Replacement117
Air Injection System Removal/Installation118
Canister And Hose Replacement118
Evaporative Emission Control118
Air Injection System View119
Air Injection System Layout120
Air Injection System Components121
Exhaust System Removal/Installation123
Exhaust System Inspection/Maintenance124
Carburetor Specifications125
Testing Charging System126
Charging System Wiring Diagram127
Alternator128
Stator Checks128
Stator Removal/Installation129
Stator Inspection130
Flywheel (Rotor) Removal/Installation130
Voltage Regulator/Rectifier132
Ignition System Troubleshooting132
Flywheel (Rotor) Testing132
Ignition Spark Test132
Ignition System Wiring Diagram133
Ignition System Diagnosis134
Pickup Coil Testing135
Pickup Coil Removal/Installation135
Ignition Coils Testing136
Ignition Coil Removal/Installation138
Ignitor Unit Check138
Ignitor Unit Removal/Installation138
Starting System139
Starter Motor Removal/Installation/Disassembly/Assembly139
Starting System Wiring Diagram140
Starter Motor Parts Location141
Armature Condition142
Starter Relay Removal/Installation144
Starting Circuit Cut-Off/Sidestand Relay Testing144
Lighting System145
Starting Circuit Neutral Switch Testing145
Headlight Replacement/Adjustment146
Speedometer Illumination Bulb Replacement146
Front/Rear Brake Light Switch Replacement147
Rear Brake Light Switch Adjustment147
Sidestand Switch Replacement147
Fuel Pump Testing148
Flasher Relay Replacement148
Fuel Pump Circuit149
Horn Removal/Installation/Testing152
Fuses152
Fuel Pump Testing/Connector152
Fuel Reserve Switch152
Electrical Specifications153
Starter Troubleshooting153
Replacement Bulbs153
Front Suspension And Steering154
Front Wheel Removal/Installation154
Front Wheel Inspection155
Front Wheel156
Front Hub Disassembly/Inspection157
Handlebar Removal/Installation158
Front Hub Assembly158
Steering Head Disassembly159
Steering Stem160
Steering Head Inspection161
Bearing Race Replacement/Assembly161
Front Forks Removal/Installation162
Steering Stem Adjustment162
Steering Stem Disassembly163
Front Fork164
Steering Stem Inspection/Assembly167
Front Suspension And Steering Specifications170
Front Suspension Tightening Torques170
Rear Wheel Removal/Installation171
Rear Wheel Parts List172
Rear Hub Disassembly173
Rear Wheel Inspection173
Rear Hub Inspection174
Shaft Drive Removal/Installation175
Rear Hub Assembly175
Rear Swing Arm176
Shaft Drive Disassembly/Inspection/Troubleshooting176
Swing Arm Parts Location176
Rear Swing Arm Removal/Installation/Inspection177
Shock Absorbers Removal/Inspection/Installation179
Rear Suspensions Specifications180
Rear Suspension Tightening Torques180
Brakes181
Master Cylinder Removal/Installation182
Master Cylinder Disassembly183
Master Cylinder Parts Location183
Master Cylinder Inspection184
Master Cylinder Assembly185
Front Brake Pad Replacement186
Brake Caliper Parts List186
Front Caliper Removal/Installation188
Caliper Rebuilding189
Caliper Inspection190
Front Brake Hose Replacement191
Front Brake Disc Removal/Installation/Inspection192
Rear Brake Pedal Assembly Removal/Installation193
Brake Specifications194
Brake Tightening Torques194
Index195
Xv535T/Tc/U/Uc/W/Ws Wiring Diagram198
Xv535A/Ac/E/Ec Wiring Diagram200
Xv535 (1988-1991 Uk) Wiring Diagram202
Xv535 (1992-On Uk) Wiring Diagram204
Xv535 (French And German) Wiring Diagram206
Contents208
Product View210
Maintenance Log211