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EAU03338 Welcome to the Yamaha world of motorcycling! As the owner of an XV535, you are benefiting from Yamaha’s vast experience and newest technology regarding the design and manufacture of high-quality products, which have earned Yamaha a reputation for dependability.
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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 information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.
EAU00009 TABLE OF CONTENTS 1 GIVE SAFETY THE RIGHT OF WAY 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX...
GIVE SAFETY THE RIGHT OF WAY GIVE SAFETY THE RIGHT OF WAY..........1-1...
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G IVE SAFETY THE RIGHT OF WAY EAU00021 Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. However, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics. Regular care and maintenance are essential for preserving value and operating condition of your motorcycle.
INSTRUMENT AND CONTROL FUNCTIONS Main switch ..................3-1 Indicator lights ..................3-1 Speedometer unit ................3-2 Handlebar switches ................3-2 Clutch lever ..................3-3 Shift pedal ..................3-4 Brake lever ..................3-4 Brake pedal ..................3-4 Fuel tank cap ..................3-5 Fuel ....................
I NSTRUMENT AND CONTROL FUNCTIONS EAU00027 1. Push. 1. High beam indicator light “ ” 2. Release. 2. Neutral indicator light “ ” EAU00028 3. Turn. 3. Turn signal indicator light “ ” Main switch EAU00055 EAU00056 The main switch controls the ignition P (Parking) Indicator lights and lighting systems.
INSTRUMENT AND CONTROL FUNCTIONS EAU00124 Turn signal switch 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...
INSTRUMENT AND CONTROL FUNCTIONS EAU00143 Start switch “ ” Push this switch to crank the engine with the starter. EC000005 CAUTION: See page 5-1 for starting instruc- tions prior to starting the engine. 1. Engine stop switch 1. Clutch lever EAU00149 2.
INSTRUMENT AND CONTROL FUNCTIONS 1. Shift pedal 1. Brake lever 1. Brake pedal EAU00157 EAU00158 EAU00162 Shift pedal Brake lever Brake pedal The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side of side of the engine and is used in com- handlebar grip.
INSTRUMENT AND CONTROL FUNCTIONS NOTE: The fuel tank cap 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.
INSTRUMENT AND CONTROL FUNCTIONS EAU00185 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfac- es or plastic parts. EAU00191 1. Starter (choke) lever Recommended fuel: EAU02976 Regular unleaded gasoline with a Starter (choke) lever research octane number of 91 or Starting a cold engine requires a richer...
INSTRUMENT AND CONTROL FUNCTIONS 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.
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INSTRUMENT AND CONTROL FUNCTIONS 1. Projection 1. Bolt ( 2) 1. Seat holder ( 2) 2. Seat holder 2. Projection ( 2) Rider seat To install the passenger seat To install the rider seat To remove the rider seat 1. Insert the projection on the rear of 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU00300 Adjusting the shock absorber assemblies Each shock absorber assembly is equipped with a spring preload adjust- ing ring. EC000015 CAUTION: Never attempt to turn an adjusting 1. Unlock. 1. Spring preload adjusting ring mechanism beyond the maximum 2.
It cuts the running engine when check this system regularly as de- the transmission is in gear and the scribed below and have a Yamaha sidestand is moved down. dealer repair it if it does not function Periodically check the operation of the properly.
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5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.
• Check vehicle for oil leakage. Final gear oil • Check vehicle for oil leakage. 6-9–6-10 • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check lever free play. Front brake • Adjust if necessary. 6-19, 6-21–6-23 •...
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• Correct if necessary. • Check operation of ignition circuit cut-off system. Sidestand switch 3-10 • If system is defective, have Yamaha dealer check vehicle. • Check fluid level. Battery 6-29–6-30 • Fill with distilled water if necessary.
2. Shift the transmission into the neu- following conditions must be met: their functions before riding. tral position. The transmission is in the neutral Consult a Yamaha dealer re- position. NOTE: garding any control or function When the transmission is in the neutral...
OPERATION AND IMPORTANT RIDING POINTS 5. After starting the engine, move the EAU01258 Starting a warm engine starter (choke) lever back halfway. Follow the same procedure as for start- ECA00045 ing a cold engine with the exception CAUTION: that the starter (choke) is not required For maximum engine life, never ac- when the engine is warm.
OPERATION AND IMPORTANT RIDING POINTS EC000048 EAU02941 Recommended shift points CAUTION: (for Switzerland only) Even with the transmission in The recommended shift points during the neutral position, do not acceleration are shown in the table coast for long periods of time below.
OPERATION AND IMPORTANT RIDING POINTS EAU00424 EAU00436 EAU00444* Tips for reducing fuel Engine break-in 0–150 km Avoid prolonged operation above consumption There is never a more important period 1/3 throttle. in the life of your engine than the period Fuel consumption depends largely on After every hour of operation, stop between 0 and 1,000 km.
If any engine trouble should occur WARNING during the engine break-in period, Since the engine and exhaust immediately have a Yamaha dealer system can become very hot, check the vehicle. park in a place where pedestri- ans or children are not likely to touch them.
PERIODIC MAINTENANCE AND MINOR REPAIR Owner’s tool kit ............6-1 Checking and lubricating the cables ....6-23 Periodic maintenance and lubrication chart ..6-2 Checking and lubricating the throttle grip and cable ..........6-24 Checking the spark plugs ........6-5 Checking and lubricating the brake and Engine oil and oil filter element ......6-7 shift pedals ............
Periodic inspection, adjustment and lu- ence required for a particular job, have brication will keep your vehicle in the a Yamaha dealer perform it for you. safest and most efficient condition pos- EW000063 sible. The most important points of in-...
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead. From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and techni- cal skills.
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING ( 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check for cracks or damage. Brake hose • Replace. (See NOTE on page 6-4.) Every 4 years • Check runout, spoke tightness and for damage. Wheels •...
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PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING ( 1,000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check oil level and vehicle for oil leakage. Final gear oil • Change. Front and rear brake • Check operation. switches Moving parts and cables • Lubricate. Lights, signals and •...
The spark plugs are important engine problems yourself. Instead, have a components, which are easy to check. Yamaha dealer check the motorcycle. Since heat and deposits will cause any 3. Check each spark plug for elec- spark plug to slowly erode, the spark...
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PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque: Spark plug: 20 Nm (2.0 m·kg) 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 a.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU02942 Engine oil and oil filter element The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter ele- ment replaced at the intervals specified in the periodic maintenance and lubri- cation chart.
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Engine oil drain bolt 1. Oil filter element cover 1. O-ring 2. Bolt ( 3) 2. Oil filter element 3. Remove the engine oil filler cap 4. Remove the oil filter element cover 5. Remove and replace the oil filter and drain bolt to drain the oil from by removing the bolts.
If any 7. Install the engine oil drain bolt, and Without oil filter element leakage is found, have a Yamaha deal- then tighten it to the specified replacement: er check and repair the motorcycle. In torque.
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PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Recommended final gear oil: The oil level should be at the brim of Hypoid gear oil SAE 80 (API GL4) the filler hole. or multi-grade hypoid gear oil 3. If the oil is below the brim of the fill- SAE 80W-90 er hole, add sufficient oil of the rec- Oil quantity:...
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Fuel tank 1. Screw 1. Air filter case cover 2. Bolt ( 3) 2. Tab 3. Lift the front of the fuel tank to po- 3. Holder EAU03715 sition it away from the air filter 4.
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PERIODIC MAINTENANCE AND MINOR REPAIR EC000082 CAUTION: Make sure that the air filter ele- ment is properly seated in the air filter case. The engine should never be op- erated without the air filter ele- ment installed, otherwise the piston(s) and/or cylinder(s) may 1.
Therefore, most car- checked and, if necessary, adjusted as buretor adjustments should be left to a follows at the intervals specified in the Yamaha dealer, who has the neces- periodic maintenance and lubrication sary professional knowledge and expe- chart.
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...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03362 CE-01E EWA00012 Tires Tire air pressure WARNING (measured on cold tires) To maximize the performance, durabil- Because loading has an enormous Load* Front Rear ity, and safe operation of your motor- impact on the handling, braking, 200 kPa 225 kPa cycle,...
If any dam- cycle cannot be guaranteed. The replacement of all wheel- age is found, have a Yamaha After extensive tests, only the and brake-related parts, includ- dealer replace the wheel. Do not tires listed below have been ap-...
PERIODIC MAINTENANCE AND MINOR REPAIR 7. Tighten the locknut at the clutch lever and the crankcase. 1. Locknut 1. Locknut 2. Clutch lever free play adjusting bolt 2. Clutch lever free play adjusting nut c. Clutch lever free play 3. If the specified clutch lever free EAU00694 play could be obtained as de- Adjusting the clutch lever free...
EW000104 After adjusting the brake lever WARNING free play, check the free play It is advisable to have a Yamaha and make sure that the brake is dealer make these adjustments. working properly. A soft or spongy feeling in the...
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PERIODIC MAINTENANCE AND MINOR REPAIR 1. Footrest 1. Brake pedal position adjusting bolt 1. Brake pedal free play adjusting nut 2. Distance between brake pedal and footrest 2. Locknut Brake pedal free play a. Brake pedal free play 1. Loosen the locknut at the brake The brake pedal free play should mea- Brake pedal position pedal.
Yamaha dealer replace the Turn the adjusting nut while holding the brake pads as a set. rear brake light switch in place. To make the brake light come on earlier, turn the adjusting nut in direction a.
PERIODIC MAINTENANCE AND MINOR REPAIR Brake fluid may deteriorate paint- EAU03238 EAU02962 Changing the brake fluid Checking and lubricating the ed surfaces or plastic parts. Al- Have a Yamaha dealer change the cables ways clean spilled fluid brake fluid at the intervals specified in The operation of all control cables and immediately.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU03209 Checking and lubricating the Recommended lubricant: Throttle cable: throttle grip and cable Engine oil The operation of the throttle grip and Throttle grip housing and grip: the condition of the throttle cable Lithium-soap-based grease should be checked before each ride, (all-purpose grease) and the cable should be lubricated or...
Recommended lubricant: Recommended lubricant: EW000113 WARNING Lithium-soap-based grease Lithium-soap-based grease If the sidestand does not move up (all-purpose grease) (all-purpose grease) and down smoothly, have a Yamaha dealer check or repair it. 6-25...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU00790 Recommended lubricant: Lubricating the rear Lithium-soap-based grease suspension (all-purpose grease) The pivoting points of the rear suspen- sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. Recommended lubricant: Molybdenum disulfide grease 6-26...
Yamaha dealer check the wheel bearings. 2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check repair steering.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. If the electrolyte is at or below 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 1.
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PERIODIC MAINTENANCE AND MINOR REPAIR away from the battery and pro- 2. If the battery will be stored for vide sufficient ventilation when more than two months, check the charging it in an enclosed specific gravity of the electrolyte at space.
4. If the fuse immediately blows If a fuse is blown, replace it as follows. again, have a Yamaha dealer 1. Turn the key to “OFF” and turn off check the electrical system. the electrical circuit in question.
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4. Place a new bulb into position, and 5. Install the bulb cover, and then then secure it with the bulb holder. connect the coupler. 6. Install the headlight unit by install- ing the screws. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 6-32...
PERIODIC MAINTENANCE AND MINOR REPAIR EAU01579 Supporting the motorcycle Since this model is 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.
3. Lift the front wheel off the ground EW000122 according to the procedure on WARNING page 6-33. It is advisable to have a Yamaha 4. Pull the wheel axle out, and then dealer service the wheel. remove the wheel. Securely support the motor-...
2. Lift the wheel up between the fork Front wheel axle pinch bolt: WARNING legs. 23 Nm (2.3 m·kg) It is advisable to have a Yamaha NOTE: dealer service the wheel. 8. Connect the speedometer cable. Make sure that there is enough space...
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PERIODIC MAINTENANCE AND MINOR REPAIR 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.
20 Nm (2.0 m·kg) self. However, should your motorcycle soap-based grease to the splines require any repair, take it to a Yamaha 8. Install the brake torque rod cotter of the final gear case and wheel dealer, whose skilled technicians have pin.
Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.
MOTORCYCLE CARE AND STORAGE Care ....................7-1 Storage ....................7-4...
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M OTORCYCLE CARE AND STORAGE EAU03412 Care Before cleaning Cleaning 1. Cover the muffler outlets with plas- ECA00010 While the open design of a motorcycle CAUTION: tic bags after the engine has reveals the attractiveness of the tech- Avoid using strong acidic wheel cooled down.
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MOTORCYCLE CARE AND STORAGE Do not use any harsh chemical For motorcycles equipped with After riding in the rain, near the sea or products on plastic parts. Be a windshield: Do not use strong on salt-sprayed roads sure to avoid using cloths or cleaners or hard sponges as Since sea salt or salt sprayed on roads sponges which have been in...
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MOTORCYCLE CARE AND STORAGE After cleaning EWA00031 NOTE: WARNING Consult a Yamaha dealer for advice on 1. Dry the motorcycle with a chamois Make sure that there is no oil or what products to use. or an absorbing cloth. wax on the brakes or tires.
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MOTORCYCLE CARE AND STORAGE Storage Long-term a. Remove the spark plug caps and Before storing your motorcycle for sev- spark plugs. eral months: b. Pour a teaspoonful of engine oil Short-term 1. Follow all the instructions in the into each spark plug bore. Always store your motorcycle in a cool, “Care”...
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MOTORCYCLE CARE AND STORAGE 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand. 7. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground.
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S PECIFICATIONS EAU01038 Specifications CS-01E Model XV535 Engine oil Dimensions Type -20 -10 10 20 30 40 50 ˚C Overall length 2,225 mm (except for N, S, SF) SAE 10W–30 2,250 mm (for N, S, SF) Overall width 780 mm SAE 10W–40...
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SPECIFICATIONS Final gear oil Gear ratio Type Hypoid gear oil SAE 80 2.714 (API GL4) or multigrade hypoid 1.900 gear oil SAE 80W-90 1.458 Quantity 0.19 L 1.167 Air filter Dry type element 0.967 Fuel Chassis Type Regular unleaded gasoline Frame type Pressed backbone Fuel tank capacity...
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SPECIFICATIONS Maximum load* 220 kg (except for A) Rear 218 kg (for A) Type Drum brake Tire air pressure Operation Right foot (measured on cold tires) Suspension Up to 90 kg* Front Telescopic fork Front 200 kPa (2.00 kg/cm , 2.00 bar) Rear Swingarm Rear...
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SPECIFICATIONS Bulb voltage, wattage quantity Headlight 12 V, 60/55 W Auxiliary light 12 V, 4 W 1 (except for GB) 12V, 3.4 W 1 (for GB) Tail/brake light 12 V, 5/21 W Front turn signal light 12 V, 21 W Rear turn signal light 12 V, 21 W Meter lighting...
SPECIFICATIONS EAU01064 Conversion table CS-02E Conversion table All specification data in this manual are listed in SI and METRIC TO IMPERIAL METRIC UNITS. Metric unit Multiplier Imperial unit Use this table to convert METRIC unit data to IMPERIAL m·kg 7.233 ft·lb m·kg 86.794...
CONSUMER INFORMATION Identification numbers ................ 9-1 Key identification number ..............9-1 Vehicle identification number ............. 9-1 Model label..................9-2...
Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. 1. Key identification number 1.
The model label is affixed to the frame 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.
I NDEX 1 0 - Air filter element, cleaning ......6-11 Engine break-in ........5-4 Light switch ..........3-3 Engine oil and oil filter element ....6-7 Engine stop switch........3-3 Battery ...........6-29 Main switch ..........3-1 Brake and clutch levers, checking and Model label ..........9-2 lubricating ..........6-25 Final gear oil..........
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