Yamaha Xv-535 Xv-1100 Virago 1987-2003 WSM Service Repair Manual

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🏷️ Basic Information Identification Make: Yamaha Model: XV1100 Virago Generation Start Year: 1987 End Year: 2003 👋 Introduction Market Position Segment: Cruiser Motorcycle Target Audience: Owners, maintenance technicians, enthusiasts seeking...

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Taper: Motorcycle

Distributeur:

UGS: 459941

Mots clés: 1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Motorcycle Motorcycles Virago XV Models Xv-1100 Xv-535 Yamaha

Variantes de produits

Description

🏷️ Basic Information

Identification

Make:

Yamaha

Model:

XV1100 Virago

Generation

Start Year:

End Year:

👋 Introduction

Market Position

Segment:

Cruiser Motorcycle

Target Audience:

Owners, maintenance technicians, enthusiasts seeking detailed repair information

Competitive Analysis

Competitors:

• Honda Shadow

• Kawasaki Vulcan

• Suzuki Intruder/Boulevard

Key Features

Virago Appeal:

Classic styling, V-twin engine, comfortable riding position, reliable engineering

Manual Value Proposition:

Essential resource for maintaining and repairing the Yamaha Virago series, enabling cost savings and extending the life of the motorcycle.

📋 Manual Details

Coverage Areas

Covered Models:

• Yamaha XV535 Virago

• Yamaha XV1100 Virago

Covered Years:

• 1987

• 1988

• 1989

• 1990

• 1991

• 1992

• 1993

• 1994

• 1995

• 1996

• 1997

• 1998

• 1999

• 2000

• 2001

• 2002

• 2003

Page Count

Estimated Pages:

Manual Type

Type:

Workshop Service Manual (WSM)

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine:

• Engine overhaul

• Top end components (cylinder head, valves, camshafts)

• Bottom end components (crankshaft, connecting rods, pistons)

• Lubrication system (oil pump, filter, passages)

• Cooling system (radiator, fans, coolant passages - N/A for air-cooled models)

• Ignition system (spark plugs, coils, CDI unit)

• Carburetion/Fuel Injection system (carburetor overhaul, jetting, fuel pump, injectors)

• Exhaust system

Transmission:

• Gearbox disassembly and reassembly

• Clutch system (operation, adjustment, replacement)

• Gear shift mechanism

• Drive shaft/Belt drive (depending on model variant)

Chassis:

• Frame and subframe inspection and repair

• Front suspension (forks, steering bearings)

• Rear suspension (shock absorbers, swingarm)

• Brake system (front and rear calipers, master cylinders, lines, pads, discs)

• Wheel and tire service (mounting, balancing, specifications)

• Steering system

Electrical:

• Wiring diagrams

• Battery and charging system (alternator, rectifier/regulator)

• Lighting system (headlight, taillight, turn signals)

• Ignition system components

• Starting system (starter motor, solenoid)

• Instrumentation and controls

• Sensors and switches

Bodywork:

• Body panel removal and installation

• Seat removal and installation

• Fuel tank removal and installation

• Fairing and cowling repair and replacement

Procedures Included

Maintenance:

• Routine service intervals

• Oil and filter changes

• Air filter cleaning/replacement

• Spark plug replacement

• Brake fluid flush and bleed

• Coolant flush and fill (where applicable)

• Cable lubrication and adjustment

• Chain/Belt adjustment and lubrication

Repair:

• Engine component replacement (pistons, rings, valves)

• Carburetor synchronization and tuning

• Clutch adjustment and replacement

• Brake caliper overhaul

• Fork seal replacement

• Shock absorber replacement

• Starter motor repair

• Wiring harness repair

Troubleshooting:

• Diagnostic procedures for common faults

• Component testing (ignition coils, sensors, starter)

• Identifying and resolving engine performance issues

• Diagnosing electrical system faults

Technical Depth

Depth:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds)

📊 Manual Specifications

File Format

Format:

Searchable Text:

Printable:

Print Quality

Quality:

High-resolution scans for clear diagrams and text

Binding Type

Binding:

N/A (Digital)

Paper Type

Type:

N/A (Digital)

⚙️ Engine Specifications

Primary Engine

Xv535 Engine Type:

45-degree V-twin, four-stroke, SOHC, 2 valves per cylinder

Xv535 Displacement:

534 cc

Xv1100 Engine Type:

75-degree V-twin, four-stroke, SOHC, 2 valves per cylinder

Xv1100 Displacement:

1063 cc

Performance

Xv535 Bore X Stroke:

76.0 mm x 58.0 mm

Xv1100 Bore X Stroke:

95.0 mm x 75.0 mm

Xv535 Compression Ratio:

9.5:1

Xv1100 Compression Ratio:

8.3:1

Xv535 Horsepower:

Approx. 44 HP @ 7500 RPM (varies by market)

Xv1100 Horsepower:

Approx. 63 HP @ 6250 RPM (varies by market)

Xv535 Torque:

Approx. 42 Nm @ 6000 RPM (varies by market)

Xv1100 Torque:

Approx. 86 Nm @ 3750 RPM (varies by market)

Fuel System

Xv535 Fuel Delivery:

Dual Mikuni B-S34 carburetors

Xv1100 Fuel Delivery:

Dual Mikuni B-S37 carburetors

Fuel Capacity:

XV535: 14.0 L (3.7 US gal); XV1100: 17.0 L (4.5 US gal)

Recommended Fuel:

Unleaded gasoline, minimum octane rating 87 (R+M)/2

🔧 Transmission

Standard

Type:

5-speed constant mesh

Drive Type:

Shaft drive

Features

Clutch Type:

Wet, multi-plate

Transmission Fluid Spec:

Yamalube SAE 20W-40 API SE Type SC or SF (or equivalent)

📐 Dimensions

Exterior

Xv535 Length:

2235 mm (88.0 in)

Xv1100 Length:

2310 mm (90.9 in)

Xv535 Width:

825 mm (32.5 in)

Xv1100 Width:

840 mm (33.1 in)

Xv535 Height:

1150 mm (45.3 in)

Xv1100 Height:

1195 mm (47.0 in)

Weights

Xv535 Dry Weight:

180 kg (397 lbs)

Xv1100 Dry Weight:

215 kg (474 lbs)

Xv535 Wet Weight:

Approx. 200 kg (441 lbs)

Xv1100 Wet Weight:

Approx. 235 kg (518 lbs)

Xv535 Seat Height:

720 mm (28.3 in)

Xv1100 Seat Height:

735 mm (28.9 in)

🛡️ Safety Features

Ratings

Safety Standards:

Compliant with prevailing motorcycle safety regulations of the era.

Active Features

Braking System:

Hydraulic disc brakes front and rear (XV535 often dual front discs, XV1100 typically dual front discs).

Tires:

Tubeless tires front and rear (specifications vary by year and trim).

Passive Features

Lighting:

Halogen headlight, taillight, brake light, front and rear turn signals.

💡 Technology Features

Infotainment

Features:

Analog instrumentation (speedometer, tachometer, fuel gauge, indicator lights). No advanced infotainment systems.

Driver Assistance

Features:

None.

Connectivity

Features:

None.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 6,000 km (3,700 miles) or 6 months, whichever comes first.

Air Filter Cleaning:

Every 6,000 km (3,700 miles) or annually.

Spark Plug Replacement:

Every 12,000 km (7,500 miles) or annually.

Major Service:

Refer to manual for specific valve clearance checks, ignition timing adjustments, and carburetor synchronization schedules (typically every 12,000-18,000 km or 7,500-11,000 miles).

Fluid Specifications

Engine Oil Capacity:

XV535: 2.7 L (2.9 US qt); XV1100: 3.4 L (3.6 US qt) with filter change.

Brake Fluid Type:

DOT 4

Final Drive Fluid Type:

Yamalube SAE 80 API GL-4 Hypoid Gear Oil (or equivalent)

Known Issues

Electrical Connectors:

Corrosion and poor contact in various electrical connectors due to age and environmental exposure.

Carburetor Issues:

Varnish buildup and sticking diaphragms in carburetors, leading to poor idle and fuel delivery problems.

Regulator Rectifier:

Failure of the regulator/rectifier unit, leading to overcharging or undercharging of the battery.

Starter Solenoid:

Sticking or failed starter solenoid, preventing the engine from cranking.

Rear Shock ABSorbers:

Wear and loss of damping in rear shock absorbers due to age and mileage.

📚 Vehicle History

Brand Heritage

Yamaha Motorcycles:

Yamaha Motor Company, established in 1955, has a long history of innovation and success in motorcycle manufacturing, known for performance, reliability, and rider-focused design.

Model Evolution

Virago Lineage:

The Virago line was Yamaha's entry into the V-twin cruiser market, aiming for classic styling with modern engineering. The XV535 and XV1100 represent mid-range and larger displacement options within this popular series.

Production

Manufacturing Location:

Primarily Japan (and potentially other Yamaha global facilities).

Significance:

The Virago series established Yamaha as a strong contender in the cruiser segment and influenced subsequent cruiser designs.

🏆 Awards & Recognition

Recognitions

Industry Reputation:

The Virago series received positive reviews for its style, comfort, and reliable V-twin engines, becoming a popular choice for cruiser enthusiasts.

Ratings

Owner Satisfaction:

Consistently high owner satisfaction for its segment during its production run.