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Yamaha VIRAGO XV535 Replacement Parts Manual 1995

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🏷️ Basic Information Identification Make: Yamaha Model: Virago XV535 Year: 1995 Product Type: OEM Parts Manual 👋 Introduction Market Position Target Audience: Yamaha Virago XV535 owners, motorcycle mechanics, and parts...
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Taper: Motorcycle
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UGS: 285521
Yamaha VIRAGO XV535 Replacement Parts Manual 1995
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Virago XV535
Year:
1995
Product Type:
OEM Parts Manual
👋 Introduction
Market Position
Target Audience:
Yamaha Virago XV535 owners, motorcycle mechanics, and parts suppliers.
Competitive Analysis
Value Proposition:
Essential resource for accurate part identification, ensuring correct repairs and maintenance, thereby prolonging the life and performance of the motorcycle.
Key Features
Illustrations:
Features detailed exploded parts diagrams for visual reference.
Part Number Listing:
Comprehensive listing of OEM part numbers for all components.
📋 Manual Details
Coverage Areas
Manual Type:
Illustrated Parts Catalog
Language:
English
Format:
Printed
Page Count
Page Count:
Unknown (typical for this era and type of manual)
📖 Manual Coverage
Systems Covered
Engine:
Complete engine assembly breakdown, including cylinder head, cylinders, pistons, crankshaft, camshafts, valves, timing components, oil pump, and related fasteners.
Fuel System:
Carburetor assemblies (including jetting, floats, needles, jets), fuel pump, fuel lines, fuel tank and petcock components.
Transmission:
Gearbox components, clutch assembly (plates, springs, basket), shift drum and forks, transmission shafts, bearings, and seals.
Chassis:
Frame components, front fork assembly (springs, dampers, seals), rear suspension (shocks, linkages), swingarm, bearings, and fasteners.
Wheels And Brakes:
Wheel hubs, spokes, rims, brake calipers, brake discs, brake master cylinders, brake levers/pedals, brake lines, and associated hardware.
Electrical System:
Ignition system components (CDI unit, ignition coils, spark plugs), lighting (headlight, taillight, indicators), wiring harnesses, battery, starter motor, alternator/stator, switches, and fuses.
Bodywork And Trim:
Fuel tank, fenders, side covers, seat assembly, handlebars, grips, levers, mirrors, exhaust system components, and decorative trim pieces.
Procedures Included
Disassembly:
Detailed exploded diagrams allowing for systematic disassembly of all major and minor components.
Assembly:
Provides the correct order and identification of parts for reassembly, crucial for proper function and fitment.
Part Identification:
Crucial for ordering correct replacement parts; includes part numbers for every component.
Technical Depth
Level Of Detail:
Extremely high, focusing on individual component identification and their place within larger assemblies.
Primary Use:
Parts identification, ordering, and visualization for repair and maintenance.
📊 Manual Specifications
File Format
Format Type:
Printed Document
Print Quality
Print Resolution:
Professional quality, designed for clarity of diagrams and text.
Binding Type
Binding:
Likely saddle-stitched or perfect bound for ease of use during disassembly/assembly.
Paper Type
Paper Quality:
Durable paper stock suitable for workshop environments, resistant to grease and dirt.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, V-twin, 4-stroke
Displacement:
498cc (30.4 cu.in.)
Bore X Stroke:
73.0 mm x 59.6 mm (2.87 in x 2.35 in)
Valve Train:
SOHC, 2 valves per cylinder
Performance
Horsepower:
Approx. 30-35 HP (Varies by market and tuning)
Torque:
Approx. 38-42 Nm (Varies by market and tuning)
Fuel System
Carburetion:
Dual Mikuni constant velocity (CV) carburetors, likely 34mm diameter (e.g., Mikuni BS34)
Fuel Capacity:
Approx. 13 Liters (3.4 US gal)
Lubrication
Oil Capacity:
Approx. 2.6 Liters (2.7 US qt) with filter change
Oil Type Specification:
Yamalube or equivalent motorcycle specific 10W-40 API SG or higher (consult specific manual for exact spec)
🔧 Transmission
Standard
Transmission Type:
5-speed constant mesh
Final Drive:
Shaft drive
Features
Clutch Type:
Wet, multi-disc
📐 Dimensions
Exterior
Length:
Approx. 2215 mm (87.2 in)
Width:
Approx. 775 mm (30.5 in)
Height:
Approx. 1160 mm (45.7 in)
Wheelbase:
Approx. 1500 mm (59.1 in)
Weights
Dry Weight:
Approx. 170 kg (375 lbs)
Gross Vehicle Weight Rating:
Not explicitly specified, but designed for rider + passenger + luggage.
Wheels And Tires
Front Tire Size:
100/90-18M/C 56S
Rear Tire Size:
130/90-15M/C 66S
Front Brake Type:
Single Disc
Rear Brake Type:
Drum Brake
🛡️ Safety Features
Ratings
Safety Features:
Reflective elements on tires and bodywork, independent braking systems.
Active Features
Lighting:
Halogen headlight, LED taillight, amber front and rear turn signals.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable; motorcycle designed for core riding experience.
Driver Assistance
Driver Assistance Features:
Not applicable; no electronic rider aids.
Connectivity
Connectivity Features:
Not applicable.
🔧 Maintenance
Service Intervals
Oil Change Interval:
Every 4,000-6,000 km (2,500-3,750 miles) or 6 months (refer to service manual for exact specification)
Spark Plug Replacement:
Typically every 10,000-12,000 km (6,250-7,500 miles)
Air Filter Cleaning:
Regular inspection, cleaning/replacement every 8,000-10,000 km (5,000-6,250 miles)
Fluid Specifications
Brake Fluid:
DOT 4
Fork Oil Type:
Yamaha Fork Oil (or equivalent SAE 10W)
Final Drive Oil:
Yamalube Gear Oil (or equivalent SAE 80W-90 API GL-4)
Known Issues
Carburetor Issues:
Aging rubber diaphragms in CV carbs can lead to poor performance; synchronization may drift over time.
Electrical Connections:
Corrosion in connectors, particularly for lighting and ignition, can cause intermittent issues.
Shaft Drive Maintenance:
Requires periodic lubrication and inspection of U-joints and final drive seals.
Common Repairs
Clutch Replacement:
Wear on clutch plates is common with high mileage, requiring replacement.
Valve Adjustment:
Periodic valve clearance checks and adjustments are necessary for optimal engine performance.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation
Model Evolution
Virago Lineage:
The Virago line was Yamaha's entry into the cruiser market, known for its V-twin engines and classic styling. The XV535 was a popular mid-displacement model.
Production
Production Era:
The XV535 was produced from the mid-1980s through the early 2000s, with minor updates over its lifespan. 1995 represents a mid-production model.
Manufacturing Location:
Primarily Japan
🏆 Awards & Recognition
Recognitions
Market Reception:
Well-regarded for its reliability, ease of maintenance, and classic cruiser styling in its segment.
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