Chapter 1 Tune-up and routine maintenance Contents Section Air filter element - servicing 14

Battery electrolyte level/specific gravity - check 4 Brake lever and pedal position and play - check
and adjustment. 7 Brake pads and shoes - wear check 5 Brake system - general check 6 Carburetor
synchronization - check and adjustment 20 Clutch - check and adjustment 10 Crankcase ventilation
system - inspection 21 Cylinder compression - check 15 Drive chain and sprockets (chain drive
models) - check, adjustment and lubrication 11 Engine oil/filter - change 13 Exhaust system - check
22 Fasteners - check 24 Final drive oil (shaft drive models) - check and change 12 Section Fluid
levels - check 3 Fuel system - check and filter cleaning or replacement 25 Idle speed - check and
adjustment 19 Introduction to tune-up and routine maintenance 2 Lubrication - general 17 Shift
linkage adjustment 27 Spark plugs - replacement 16 Steering head bearings - check, adjustment
and lubrication 23 Suspension adjustments 28 Suspension - check 26 Throttle and choke
operation/grip freeplay - check . and adjustment 9 Tires/wheels - general check 8 Valve clearances
- check and adjustment 18 Yamaha XV Routine maintenance intervals 1 1-2 Chapter 1 Tune-up and
routine maintenance Specifications XV535 Engine Spark plugs Type NGK BP7ES or ND W22EP-U
Gap 0.7 to 0.8 mm (0.028 to 0.032 inch) Valve clearances (COLD engine) Intake 0.07 to 0.12 mm
(0.003 to 0.005 inch) Exhaust 0.12 to 0.17 mm (0.005 to 0.007 inch) Engine idle speed 1150 to
1250 rpm Cylinder compression pressure (at sea level) Standard 10.75 Bars (156 psi) Maximum...
11.78 Bars (171 psi) Minimum 9.78 Bars (142 psi) Maximum difference between cylinders 0.96
Bars (14 psi) Carburetor synchronization Vacuum at idle speed 230 mm Hg (9.06 inch Hg)
Maximum vacuum difference between cylinders 10 mm Hg (0.39 inch Hg) Cylinder numbering
(from rear to front of bike)... 1-2 Miscellaneous Brake pedal position.. . 38 mm (1.5 inch) above the
top of the footpeg Shift pedal position 50 to 60 mm (2.0 to 2.4 inches) above the top of the
footpeg Freeplay adjustments Throttle grip 2 to 5 mm (0.08 to 0.20 inch) Clutch lever 2 to 3 mm
(0.08 to 0.12 inch) Front brake lever 2 to 5 mm (0.08 to 0.20 inch) Rear brake pedal .... 20 to 30
mm (0.8 to 1.2 inches) Battery electrolyte specific gravity 1.280 at 20-degrees C (68-degrees F)
Minimum tire tread depth* 1 mm (0.04 inch) Tire pressures (cold) Front 1987 and 1988 US, all UK
models... 1.93 Bars (28 psi) 1989 and later US models 1.99 Bars (29 psi) Rear Up to 90 kg (198 lbs)
1987 and 1988 US, all UK models 2.2 Bars (32 psi) 1989 and later US models . 2.27 Bars (33 psi)
Above 90 kg (198 lbs) or high speed riding 2.48 bars (36 psi) Torque specifications Oil drain plug 43
Nm (31 ft-lbs) Oil filter cover bolts 10 Nm (7.2 ft-lbs) Spark plugs 12.5 Nm (9 ft-lbs) Steering head
bearing ring nuts Initial torque 38 Nm (27 ft-lbs) Final torque 10 Nm (7.2 ft-lbs) Steering stem bolt
54 Nm (39 ft-lbs) Valve adjuster locknuts . 14 Nm (10 ft-lbs) Rocker cover bolts 10 Nm (7.2 ft-lbs)
Final drive filler and drain plugs 23 Nm (17 ft-lbs) Recommended lubricants and fluids Fuel type US
. Unleaded UK Regular Fuel capacity 1987 and 1988 models Total......... 8.6 liters (2.3 US gal, 1.9
Imp gal) Reserve 2.0 liters (0.5 US gal, 0.4 Imp gal) 1989 and later models Total . 13.5 liters (3.6 US
gal, 3.0 Imp gal) Reserve.. 2.5 liters (0.7 US gal, 0.5 Imp gal) Engine/transmission oil Type API grade
SE or SF Chapter 1 Tune-up and routine maintenance 1-3 Viscosity Consistently below 15 degrees
C (60 degrees F) SAE 10W30 Consistently above 5 degrees C (40 degrees F) SAE 20W40 Capacity
With filter change 2.8 liters (3.0 US qt, 5.0 Imperial pt) Oil change only 2.6 liters (2.7 US qt, 4.6
Imperial pt) Brake fluid .. DOT 4 Final gear Type SAE 80 API GL-4 hypoid gear oil Capacity 0.19 liters
(0.2 US qt, 0.34 Imp pt Wheel bearings Medium weight, lithium-based multi-purpose grease
Swingarm pivot bearings . Medium weight, lithium-based multi-purpose grease Cables and lever
pivots Chain and cable lubricant or 10W30 motor oil Sidestand/centerstand pivots Chain and cable
lubricant or 10W30 motor oil Brake pedal/shift lever pivots Chain and cable lubricant or 10W30
motor oil Throttle grip Multi-purpose grease or dry film lubricant 'In the UK, tread depth must be
at least 1 mm over 3/4 of the tread breadth all the way around the tire, with no bald patches.
1981 through 1983 XV750 through 1000 models and all TR1 Engine Spark plugs Type NGK BP7ES or
ND W22EP-U Gap... 0.7 to 0.8 mm (0.028 to 0.032 inch) Valve clearances (COLD engine) Intake
0.10 mm (0.004 inch) Exhaust 0.15 mm (0.006 inch) Engine idle speed .. 950 to 1050 rpm Cylinder
compression pressure (at sea level) XV750 and TR1 Not specified XV920 . 9.30 Bars (135 psi) at 300
rpm Carburetor synchronization Vacuum at idle speed " 180 +/-10 mm Hg (7.09 +/- 0.4 inch Hg)
Maximum vacuum difference between cylinders 10 mm Hg (0.4 inch Hg) Cylinder numbering (from
rear to front of bike) 1-2 Miscellaneous Brake pedal position Not specified Shift pedal position Not
specified Freeplay adjustments Throttle grip Not specified Clutch lever 2 to 3 mm (0.08 to 0.12
inch) Front brake lever 5 to 8 mm (0.20 to 0.30 inch) Rear brake pedal 20 to 30 mm (0.8 to 1.2
inches) Battery electrolyte specific gravity 1.280 at 20-degrees C (68-degrees F) Minimum tire
tread depth* 1 mm (0.04 inch) Tire pressures (cold) XV750, XV920 K and MK Front Up to 90 kg
(198 lbs) load 1.79 Bars (26 psi) 90 to 160 kg (198 to 353 lbs) load 1.93 Bars (28 psi) High speed
riding 2.20 Bars (32 psi) Rear Up to 90 kg (198 lbs) 1.93 Bars (28 psi) 90 to 160 kg (198 to 353 lbs)
2.48 bars (36 psi) High speed riding 2.20 Bars (32 psi) XV920J Front ' Up to 90 kg (198 lbs) load 1.79
Bars (26 psi) 90 to 213 kg (198 to 470 lbs) load 1.93 Bars (28 psi) High speed riding 2.20 Bars (32
psi) Rear Up to 90 kg (198 lbs) 1.93 Bars (28 psi) 90 to 213 kg (198 to 470 lbs) 2.76 bars (40 psi)
High speed riding 2.48 Bars (36 psi) 1-4 Chapter 1 Tune-up and routine maintenance Tire pressures
(cold) (continued) XV920RH and RJ Front Up to 90 kg (198 lbs) load 1.79 Bars (26 psi) 90 to 213 kg
(198 to 470 lbs) load 1.93 Bars (28 psi) High speed riding 1.93 Bars (28 psi) Rear Up to 90 kg (198
lbs) 1.93 Bars (28 psi) 90 to 213 kg (198 to 470 lbs) 2.20 bars (32 psi) High speed riding 2.20 Bars
(32 psi) TR1 (XV1000 chain drive) models Front Up to 90 kg (198 lbs) load . 1.79 Bars (26 psi) 90 to
201 kg (198 to 443 lbs) load 1.93 Bars (28 psi) High speed riding . 1.93 Bars (28 psi) Rear Up to 90
kg (198 lbs) . 1.93 Bars (28 psi) 90 to 201 kg (198 to 443 lbs) 2.20 bars (32 psi) High speed riding
2.20 Bars (32 psi) Torque specifications Oil drain plug 43 Nm (31 ft-lbs) Oil filter cover bolts 10 Nm
(7.2 ft-lbs) Spark plugs 14 Nm (10 ft-lbs) Steering head bearing ring nuts Initial torque 25 Nm (18
ft-lbs) Final torque Back off 1/4 turn Steering stem bolt XV920J, K, MK 54 Nm (39 ft-lbs) All others
50 Nm (36 ft-lbs) Valve adjuster locknuts 27 Nm (19 ft-lbs) Rocker cover bolts 10 Nm (7.2 ft-lbs)
Final drive filler and drain plugs 23 Nm (17 ft-lbs) Recommended lubricants and fluids
Engine/transmission oil Type API grade SE or SF Viscosity Consistently below 15 degrees C (60
degrees F) SAE 10W30 Consistently above 5 degrees C (40 degrees F) SAE 20W40 Capacity With
filter change 3.1 liters (3.3 US qt, 5.46 Imperial pt) Oil change only 3.0 liters (3.2 US qt, 5.28
Imperial pt) Brake fluid DOT 4 Final gear Type SAE 80 API GL-4 hypoid gear oil Capacity 0.20 liters
(6.76 US fl oz, 7.04 Imp fl oz Wheel bearings Medium weight, lithium-based multi-purpose grease
Swingarm pivot bearings Medium weight, lithium-based multi-purpose grease Cables and lever
pivots Chain and cable lubricant or 10W30 motor oil Sidestand/centerstand pivots Chain and cable
lubricant or 10W30 motor oil Brake pedal/shift lever pivots Chain and cable lubricant or 10W30
motor oil Throttle grip Multi-purpose grease or dry film lubricant *ln the UK, tread depth must be
at least 1 mm over 3/4 of the tread breadth all the way around the tire, with no bald patches.
1984 and later models Engine Spark plugs Type NGK BP7ES or ND W22EP-U Gap 0.7 to 0.8 mm
(0.028 to 0.032 inch) Valve clearances (COLD engine) Intake 0.07 to 0.12 mm (0.003 to 0.005 inch)
Exhaust . 0.12 to 0.17 mm (0.005 to 0.007 inch) Engine idle speed . 950 to 1050 rpm Chapter 1
Tune-up and routine maintenance 1-5 Cylinder compression pressure (at sea level) Standard 10.75
Bars (156 psi) Maximum 11.78 Bars (171 psi) Minimum . 8.8 Bars (128 psi) Maximum difference
between cylinders 0.96 Bars (14 psi) Carburetor synchronization Vacuum at idle speed 180 +/-10
mm Hg (7.09 +/- 0.4 inch Hg) Maximum vacuum difference between cylinders 10 mm Hg (0.4 inch
Hg) Engine idle speed 950 to 1050 rpm Cylinder numbering (from rear to front of bike) 1-2
Miscellaneous Brake pedal position 20 mm (0.8 inch) above bottom of footpeg Shift pedal position
. Not specified Freeplay adjustments Throttle grip Not specified Clutch lever 2 to 3 mm (0.08 to
0.12 inch) Front brake lever 5 to 8 mm (0.20 to 0.30 inch) Rear brake pedal 20 to 30 mm (0.8 to 1.2
inch) Battery electrolyte specific gravity 1.280 at 20-degrees C (68-degrees F) Minimum tire tread
depth* 1 mm (0.04 inch) Tire pressures (cold) Front Up to 90 kg (198 lbs) load 1.79 Bars (26 psi) 90
kg to maximum load 1.93 Bars (28 psi) High speed riding 2.20 Bars (32 psi) Rea r Up to 90 kg (198
lbs) 1.93 Bars (28 psi) 90 to 160 kg (198 to 353 lbs) 2.48 bars (36 psi) 160 kg (353 lbs) to maximum
load 2.76 Bars (40 psi) High speed riding 2.48 Bars (36 psi) Torque specifications Oil drain plug 43
Nm (31 ft-lbs) Oil filter cover bolts 10 Nm (7.2 ft-lbs) Spark plugs 20 Nm (14 ft-lbs) Steering head
bearing ring nuts Initial torque 50 Nm (36 ft-lbs) Final torque 3 Nm (2.2 ft-lbs) Steering stem nut...
110 Nm (80 ft-lbs) Valve adjuster locknuts .. 27 Nm (19 ft-lbs) Rocker cover bolts 10 Nm (7.2 ft-lbs)
Final drive filler and drain plugs....... 23 Nm (17 ft-lbs) Recommended lubricants and fluids
Engine/transmission oil Type API grade SE or SF Viscosity Consistently below 15 degrees C (60
degrees F) SAE 10W30 Consistently above 5 degrees C (40 degrees F) SAE 20W40 Capacity With
filter change 3.1 liters (3.3 US qt, 5.46 Imperial pt) Oil change only 3.0 liters (3.2 US qt, 5.28
Imperial pt) Brake fluid DOT 4 Final gear Type SAE 80 API GL-4 hypoid gear oil Capacity 0.20 liters
(6.76 US fl oz, 7.04 Imp fl oz Wheel bearings Medium weight, lithium-based multi-purpose grease
Swingarm pivot bearings Medium weight, lithium-based multi-purpose grease Cables and lever
pivots Chain and cable lubricant or 10W30 motor oil Sidestand/centerstand pivots Chain and cable
lubricant or 10W30 motor oil Brake pedal/shift lever pivots . Chain and cable lubricant or 10W30
motor oil Throttle grip Multi-purpose grease or dry film lubricant *In the UK, tread depth must be
at least 1 mm over 3/4 of the tread breadth all the way around the tire, with no bald patches.