🏷️ Basic Information

Make:

Yamaha

Model:

Virago XV535

Product Type:

Service Repair Workshop Manual

Model Codes:

XV535

👋 Introduction

Positioning:

The Yamaha Virago XV535 was a popular mid-size cruiser known for its V-twin engine, comfortable riding position, and classic styling, appealing to both new and experienced riders seeking a reliable and stylish machine.

Competitors:

Competed with models like the Honda Shadow VT500/VT600, Kawasaki Vulcan 500, and Suzuki Intruder VS700/VS750.

Engine Type:

Air-cooled, 72-degree V-twin.

Drivetrain:

Shaft drive for low maintenance.

Styling:

Classic cruiser aesthetic with teardrop fuel tank, pulled-back handlebars, and custom-style seat.

Savings:

Empowers owners to perform routine maintenance and repairs, significantly reducing dealership service costs.

📋 Manual Details

Applicable Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Estimated Page Count:

300+

Type:

Comprehensive Service and Repair Manual

Language:

English

Format:

Digital Download (PDF)

📖 Manual Coverage

Engine:

Complete engine disassembly, assembly, troubleshooting, tuning, lubrication, cooling system.

Fuel System:

Carburetor overhaul and adjustment (Mikuni VM series), fuel pump, fuel lines, fuel tank maintenance.

Ignition System:

CDI ignition, spark plugs, ignition timing, troubleshooting.

Transmission Drivetrain:

Clutch operation and service, gearbox disassembly and assembly, final drive maintenance (shaft drive), universal joints.

Suspension:

Front fork overhaul and service (including seals and oil), rear shock absorber inspection and replacement, linkage maintenance.

Brakes:

Front and rear brake systems (disc and drum), brake caliper overhaul, master cylinder service, brake fluid replacement and bleeding.

Electrical System:

Wiring diagrams, battery maintenance, starter motor, alternator, lighting system, fuses, relays, troubleshooting electrical faults.

Cooling System:

Air-cooled engine operation and maintenance.

Frame Chassis:

Frame inspection, steering head bearing service, swingarm inspection and maintenance.

Bodywork Fittings:

Fender removal/installation, seat, fuel tank removal/installation, trim pieces.

Maintenance:

Routine checks, lubrication, filter replacement, fluid changes, chain adjustment (if applicable to specific model variants, though XV535 is shaft-driven).

Troubleshooting:

Diagnostic procedures for common problems, fault finding guides.

Repair:

Step-by-step instructions for component repair and replacement.

Rebuilding:

Detailed instructions for engine and gearbox rebuilding.

Restoration:

Guidance for bringing the motorcycle back to original specifications.

Diagnostics:

Comprehensive diagnostic charts and symptom-based troubleshooting.

Depth:

Covers everything from basic fluid checks and adjustments to complete engine and transmission rebuilds, electrical system diagnosis, and chassis component overhauls.

📊 Manual Specifications

Quality:

High-resolution, clear text and images for easy reading and printing.

Searchability:

Fully searchable PDF for quick access to information.

Printability:

Designed for printing individual sections or the entire manual.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Type:

Four-stroke, air-cooled, 72° V-twin

Displacement:

535 cc (32.6 cu in)

Bore X Stroke:

76.0 mm x 58.0 mm (3.0 x 2.3 in)

Compression Ratio:

9.2:1

Valvetrain:

SOHC, 2 valves per cylinder

Horsepower:

Approx. 44 hp @ 7500 rpm (varies by market/spec)

Torque:

Approx. 43 Nm (31.7 lb-ft) @ 5500 rpm (varies by market/spec)

Carburetion:

Dual Mikuni VM34SS constant velocity carburetors

Fuel Tank Capacity:

9.0 L (2.4 US gal)

Oil Capacity:

2.4 L (2.5 US qt) with filter change

Recommended Oil Type:

Yamalube 4 (or equivalent) SAE 10W-40 API SE, SF, or SG (refer to manual for precise specifications)

🔧 Transmission

Type:

5-speed constant mesh

Drivetrain:

Shaft drive

Primary Reduction:

2.045 (45/22)

Final Drive Ratio:

3.000 (42/14)

Transmission Oil Type:

Yamalube 4 (or equivalent) SAE 80 API GL-4

Transmission Oil Capacity:

0.4 L (0.42 US qt)

📐 Dimensions

Length:

2205 mm (86.8 in)

Width:

770 mm (30.3 in)

Height:

1125 mm (44.3 in)

Wheelbase:

1500 mm (59.1 in)

Ground Clearance:

150 mm (5.9 in)

Seat Height:

710 mm (28.0 in)

Front Tire Size:

100/90-18M/C 56H

Rear Tire Size:

140/90-15M/C 70H

Wheel Type:

Spoked or cast aluminum (depending on trim/market)

Dry Weight:

171 kg (377 lbs)

Wet Weight:

183 kg (403 lbs) (approximate)

Payload Capacity:

170 kg (375 lbs) (rider + passenger + luggage)

🛡️ Safety Features

Crash Safety:

N/A (Motorcycles are not rated by NHTSA/IIHS)

Braking System:

Front: 2-piston caliper, 298mm disc; Rear: Drum brake

Lighting:

Halogen headlight, taillight, brake light, turn signals.

💡 Technology Features

Audio System:

N/A (No integrated infotainment system)

Gauge Cluster:

Analog speedometer, tachometer, odometer, trip meter, engine temperature warning light, oil pressure warning light, neutral indicator, turn signal indicators.

🔧 Maintenance

Oil Change:

Every 4,000 km (2,500 miles) or 6 months

Oil Filter Change:

Every oil change (or as per manual)

Air Filter Cleaning:

Every 4,000 km (2,500 miles)

Spark Plug Replacement:

Every 10,000 km (6,000 miles)

Valve Clearance Check:

Every 10,000 km (6,000 miles)

Brake Fluid Change:

Every 2 years

Engine Oil Grade:

SAE 10W-40 (API SG or higher)

Brake Fluid Type:

DOT 3 or DOT 4 (refer to manual for specific type)

Carburetor Issues:

Mikuni VM34SS carburetors can be prone to wear over time, leading to synchronization issues or fuel delivery problems if not maintained. Gumming due to old fuel is common.

Electrical Gremlins:

As with many bikes of this era, wiring connections can corrode, leading to intermittent electrical faults. Checking grounds and connector integrity is crucial.

Rear Drum Brake:

Rear drum brake performance can be less potent than modern disc brakes and requires proper adjustment and maintenance.

Clutch Cable:

Clutch cable adjustment and lubrication are important for smooth operation.

📚 Vehicle History

Yamaha Legacy:

Yamaha has a long-standing reputation for producing high-quality, reliable motorcycles, known for their innovation in engine technology and performance across various segments.

Virago Lineage:

The Virago line, introduced in the early 1980s, aimed to capture the growing cruiser market with its V-twin engines and American-inspired styling. The XV535 was a significant model within this range, offering a more accessible displacement for a broader audience.

Production Period:

1987-2003

Manufacturing Locations:

Primarily Japan

🏆 Awards & Recognition

Awards:

While specific awards are not widely publicized for this model, it was consistently recognized by motorcycle enthusiasts and publications for its value, reliability, and classic cruiser appeal during its production run.