1987-2003 Yamaha Virago XV535 Service & Repair Manual

CLYMER M395-10 YAMAHA XV535-1100 VIRAGO • 1981-2003 SERVICE • REPAIR • MAINTENANCE A PRIMEDIA Publication

CLYMER YAMAHA The world's finest publisher of mechanical how-to manuals PRIMEDIA Business Directories & Books P.O. Box 12901, Overland Park, Kansas 66282-2901 Section One:XV700-1100 Virago • 1981-1999 Section Two: XV535 Virago • 1987-2003

Copyright ©2004 PRIMEDIA Business Magazines & Media Inc. FIRST EDITION First Printing February, 1986 SECOND EDITION Revised to include 1985 and 1986 models First Printing November, 1986 THIRD EDITION Revised to include 1987 models First Printing September, 1987 Second Printing April, 1988 Third Printing October, 1988 FOURTH EDITION Revised by Ed Scott to include 1988-1990 models First Printing First Printing February, 1991 Second Printing December, 1991 FIFTH EDITION Revised by Ed Scott to include 1992 models First Printing November, 1992 SIXTH EDITION Revised by Ed Scott to include 1987-1993 XV535 models and 1993 XV750 and XVI100 models First Printing October, 1993 Second Printing Second Printing June, 1994 SEVENTH EDITION Revised to include 1994-1995 models First Printing April, 1995 Second Printing March, 1996 EIGHTH EDITION First Printing June, 1997 Second Printing January, 1998 NINTH EDITION Revised to include 1998-1999 models First Printing June, 1999 Second Printing August, 2000 Third Printing September, 2001 Fourth Printing November, 2002 TENTH EDITION Revised to include 2000-2003 models First Printing May, 2004 Printed in U.S.A. CLYMER and colophon are registered trademarks of PRIMED1A Business Magazines & Media Inc. ISBN: 0-89287-907-6 Library of Congress: 2004092777 MEMBER MOTORCYCLE INDUSTRY COUNCIL, INC. AUTHOR: Ed Scott. TECHNICAL PHOTOGRAPHY: Ron Wright and Ed Scott. TECHNICAL ILLUSTRATIONS: Steve Amos. WIRING DIAGRAMS: Robert Caldwell. TOOLS AND EQUIPMENT: K& L Supply at www.klsupply.com. COVER: Mark Clifford Photography, Los Angeles, California. All rights reserved. Reproduction or use, without express permission, of editorial or pictorial content, in any manner, is prohibited. No patent liability is assumed with respect to the use of the information contained herein. While every precaution has been taken in the preparation of this book, the publisher assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from use of the information contained herein. Publication of the servicing information in this manual does not imply approval of the manufacturers of the products covered. All instructions and diagrams have been checked for accuracy and ease of application; however, success and safety in working with tools depend to a great extent upon individual accuracy, skill and caution. For this reason, the publishers are not able to guarantee the result of any procedure contained herein. Nor can they assume responsibility for any damage to property or injury to persons occa- sioned from the procedures. Persons engaging in the procedure do so entirely at their own risk.

Chapter One General Information Chapter Two Troubleshooting Chapter Three Lubrication, Maintenance and Tune-up Chapter Four Engine Chapter Five Clutch and Transmission Chapter Six Fuel and Exhaust Systems Chapter Seven Electrical System Chapter Eight Front Suspension and Steering Chapter Nine Rear Suspension Chapter Ten Brakes Chapter Eleven Suspension Adjustment Index Wiring Diagrams

CLYMER. Publisher Shawn Etheridge EDITORIAL Managing Editor James Grooms Associate Editor Jason Beaver Lee Buell Technical Writers Jay Bogart Michael Morlan George Parise Mark Rolling Ed Scott Ron Wright Editorial Production Manager Dylan Goodwin Senior Production Editor Greg Araujo Production Editors Holly Messinger Shara Pierceall Darin Watson Associate Production Editor Susan Hartington Julie Jantzer Justin Marciniak Technical Illustrators Steve Amos Errol McCarthy Mitzi McCarthy Bob Meyer Mike Rose MARKETING/SALES AND ADMINISTRATION Advertising & Promotions Manager Elda Starke Advertising & Promotions Coordinators ' Melissa Abbott Wendy Stringfellow Art Director Chris Paxton Sales Managers Ted Metzger, Manuals Dutch Sadler, Marine Matt Tusken, Motorcycles Business Manager Ron Rogers Customer Service Manager Terri Cannon Customer Service Supervisor Ed McCarty Customer Service Representatives Shawna Davis Courtney Hollars '",-• Susan Kohlmeyer April LeBlond Jennifer Lassiter Ernesto Suarez Warehouse & Inventory Manager Leah Hicks PRIMEDIA Business Magazines & Media P.O. Box 12901, Overland Park, KS 66282-2901 • 800-262-1954 • 913-967-1719 The following books and guides are published by PRIMEDIA Business Directories & Books. CLYMER. More information available at primediabooks.com

CLYMER The XV535 Virago 1987-2003 models are covered in Section Two of this book. YAMAHA Section One:XV700-1100 Virago • 1981-1999

CONTENTS— Section One XV700-1100 Virago • 1981-1999 QUICK REFERENCE DATA IX CHAPTER ONE GENERAL INFORMATION 1 Operating requirements Troubleshooting instruments Emergency troubleshooting Engine starting Engine performance Engine noises Excessive vibration Clutch Transmission Front suspension and steering Brake problems Electrical problems Ignition system Lubrication Maintenance Drive chain Tune-up Manual organization Service hints Torque specifications Safety first Special tips Expendable supplies Parts replacement Serial numbers Basic hand tools Tune-up and troubleshooting tools Mechanic's tips CHAPTER TWO TROUBLESHOOTING 16 CHAPTER THREE LUBRICATION, MAINTENANCE AND TUNE-UP 20 Routine checks Maintenance intervals Tires and wheels Battery

CHAPTER FOUR ENGINE 56 Engine principles Servicing in frame Engine removal/installation Cylinder heads and camshafts Valves and valve components Rocker arm assemblies Cylinder Pistons and piston rings Oil pump/strainer Oil pressure relief valve Oil level switch Neutral switch Timing gears Primary drive gear Crankcase Crankshaft and connecting rods Middle drive gear Starter gears Break-in Clutch Clutch cable Drive sprocket CHAPTER FIVE CLUTCH AND TRANSMISSION 100 Shift mechanism Transmission Shift drum and forks Air cleaner Carburetors Coasting enrichener system Fuel level measurement Choke cable adjustment Rejetting carburetors Throttle cable replacement Choke cable replacement CHAPTER SIX FUEL AND EXHAUST SYSTEMS 116 Fuel shutoff valve Fuel filter Fuel pump Fuel tank Crankcase breather system Mixture control valve Air induction system Exhaust system CHAPTER SEVEN ELECTRICAL SYSTEM 145 Charging system Alternator Voltage regulator/rectifier Ignition system Ignitor unit Ignition coil Pickup coil Spark plugs Pressure sensor Starting system Electrical components Lighting system Switches Computerized monitor system Fuel pump testing Fuel warning light system Horn Fuses

Front wheel Front hub Wheel balance Wire wheel service Tire changing CHAPTER EIGHT FRONT SUSPENSION AND STEERING 190 Tire repairs Handlebar Handlebar adjustment Steering head Front fork Rear wheel Rear hub Clutch hub Drive chain assembly Wheel balancing CHAPTER NINE REAR SUSPENSION AND FINAL DRIVE 216 Tire changing Final shaft drive unit Swing arm Shock absorbers CHAPTER TEN BRAKES 233 Front brake disc Rear drum brake Rear brake pedal assembly Bleeding the system CHAPTER ELEVEN SUSPENSION ADJUSTMENT 250 Front disc brake Master cylinder Front brake pad replacement Front caliper Front brake hose replacement INDEX 255 WIRING DIAGRAMS 257 Front fork Rear shock absorbers

QUICK REFERENCE DATA XV700-1100 FUSES Main XV920J,XV1100 All others Headlight Signal Ignition Tail Reserve XV700, XV1000, XV1100 XV920J All other models Amperage 30 20 15 15 10 10 20 30 Not specified. APPROXIMATE REFILL CAPACITIES Engine oil With filter change Without filter change Engine rebuild Front fork XV700 (1984-1985) XV700 (1986-1987) XV750 (1981-1983) XV750 (1988-1994) XV920 (1981-1982 chain drive) XV920 (1982-1983 shaft drive) XV1000,XV1100 Final gear case (if so equipped) 3.3 quarts (3,100 cc) 3.2 quarts (3,000 cc) 3.8 quarts (3,600 cc) *' 13.2 oz. (389 cc) 13.4 oz. (396 cc) 9.4 oz. (278 cc) 13.4 oz. (396 cc) 8.9 oz. (264 cc) 10.2 oz. (303 cc) 12.6 oz. (372 cc) 0.21 qt. (200 cc) RECOMMENDED LUBRICANTS Engine oil 40° F and above 40° F and below Brake fluid Battery refilling Fork oil Cables and pivot points Fuel Final gear oil (if so equipped) All weather Above 40° F Below 40° F Drive chain (if so equipped) SAE 20W/40, SE-SF SAE10W/30,SE-SF DOT 3 or DOT 4 Distilled water SAE 10 Yamaha chain and cable lube or SAE 10W/30 motor oil , Regular / / SAE 80W/90, GL4 / SA 90, GL4 / SAE 80, GL4 Shell Aivania 1 or lithium-base EP2 grease XI

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1987-2003 Yamaha Virago XV535 Service & Repair Manual

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