🏷️ Basic Information

Make:

Yamaha

Model:

XV535 Virago, XV1100 Virago

Product Name:

Yamaha XV-535 XV-1100 Virago 1987-2003 Factory Service Repair Manual

Vehicle Codes:

XV535, XV1100

👋 Introduction

Market Segment:

Cruiser motorcycle segment, known for their relaxed riding position, V-twin engines, and classic styling.

Key Competitors:

Honda Shadow, Suzuki Intruder, Kawasaki Vulcan models of similar displacement and era.

Virago Philosophy:

The Virago line represented Yamaha's entry and significant success in the V-twin cruiser market, blending Japanese engineering with American styling cues.

📋 Manual Details

Model Years Covered:

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

Estimated Page Count:

400-600 (typical for comprehensive factory service manuals)

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Engine Service:

Complete engine disassembly, inspection, repair, and reassembly for both XV535 and XV1100 models. Includes cylinder head, piston, crankshaft, valve train, lubrication system, cooling system (air-cooled for XV535, liquid-cooled for XV1100).

Fuel System:

Carburetor service (removal, cleaning, adjustment, synchronization), fuel pump operation, fuel tank inspection, fuel filter replacement.

Transmission Drivetrain:

Clutch operation and adjustment, transmission disassembly and reassembly, gear inspection, final drive (shaft drive) maintenance, U-joint lubrication.

Electrical System:

Wiring diagrams, battery service, charging system (stator, regulator/rectifier), ignition system (CDI, coils, spark plugs), lighting (headlight, taillight, signals), starter system, fuses, switches.

Brakes:

Front and rear brake systems (hydraulic, drum for some rear applications). Includes brake caliper service, master cylinder service, brake pad/shoe replacement, brake fluid flushing, drum brake adjustment.

Suspension Steering:

Front fork service (oil changes, seal replacement, spring inspection), rear shock absorber service and adjustment, steering head bearing inspection and adjustment, wheel bearing service.

Bodywork Chassis:

Frame inspection, mounting hardware torque specifications, seat removal, fuel tank removal/installation, fender service, exhaust system maintenance.

Cooling System:

Specific to XV1100: Radiator service, fan operation, coolant specifications and flush procedures. XV535 is air-cooled, so this section will focus on airflow and fins.

Scheduled Maintenance:

Detailed breakdown of routine maintenance tasks based on mileage or time intervals, including oil changes, filter replacements, chain/shaft drive lubrication, brake checks, and general inspections.

Troubleshooting:

Diagnostic charts and flowcharts for common problems related to starting, running, electrical issues, and performance anomalies.

Repair Procedures:

Step-by-step instructions for disassembly, part replacement, and reassembly of all major and minor components, supported by clear diagrams and torque specifications.

Technical Specifications:

Comprehensive data including torque values, clearances, fluid capacities, electrical resistance values, and performance benchmarks.

Depth Of Coverage:

Factory-level detail, covering everything from basic adjustments and fluid changes to complete engine and transmission overhauls, electrical system diagnostics, and chassis component rebuilds.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution scans of original factory manuals, ensuring clarity of text and diagrams. Searchable text functionality is expected.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Engine Type:

Air-cooled, 4-stroke, V-twin

Displacement Cc:

534

Bore X Stroke Mm:

76.0 x 58.0

Compression Ratio:

9.0:1

Horsepower Ps:

approx. 47 PS (varies by year and market)

Torque Nm:

approx. 44 Nm @ 5500 rpm (varies by year and market)

Engine Type:

Air-cooled, 4-stroke, V-twin

Displacement Cc:

1063

Bore X Stroke Mm:

95.0 x 75.0

Compression Ratio:

8.5:1

Horsepower Ps:

approx. 65 PS (varies by year and market)

Torque Nm:

approx. 86 Nm @ 4000 rpm (varies by year and market)

Carburetor Type Xv535:

Twin Mikuni BS32

Carburetor Type Xv1100:

Twin Mikuni BS34

Ignition System:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Transmission Type:

5-speed constant mesh

Final Drive:

Shaft Drive

Clutch Type:

Wet, multiple disc

📐 Dimensions

Overall Length Mm:

approx. 2235

Overall Width Mm:

approx. 770

Seat Height Mm:

approx. 725

Overall Length Mm:

approx. 2300

Overall Width Mm:

approx. 800

Seat Height Mm:

approx. 740

Dry Weight Kg Xv535:

approx. 178

Dry Weight Kg Xv1100:

approx. 210

Fuel Tank Capacity Liters:

approx. 14.0 (XV535), 16.0 (XV1100)

🛡️ Safety Features

Safety Ratings:

Motorcycles from this era generally do not have standardized crash test ratings like automobiles. Safety is primarily addressed through design and component integrity.

Braking System:

Dual disc front brakes on most XV1100, single disc front and drum rear on many XV535. ABS was not commonly available on these models during the specified period.

Frame Construction:

Steel double-cradle frame for stability and rigidity.

💡 Technology Features

Infotainment Features:

Basic instrumentation (speedometer, odometer, tachometer on some models), analog gauges.

Assistance Systems:

No advanced electronic rider aids typical of modern motorcycles. Focus is on mechanical reliability.

Connectivity Features:

None.

🔧 Maintenance

Engine Oil Change:

Typically every 3,000-5,000 km (or annually), refer to manual for specific recommendation.

Air Filter Cleaning:

Every 5,000-10,000 km, or as needed based on riding conditions. Replacement recommended at intervals specified in the manual.

Spark Plug Replacement:

Typically every 10,000-15,000 km, refer to manual for specific type and gap.

Brake Fluid Flush:

Every 2 years or as per manual recommendation, using DOT 4 fluid.

Engine Oil Type Xv535:

Yamaha Recommend 20W-40 or 10W-40 API SG or higher. Check manual for precise specification.

Engine Oil Type Xv1100:

Yamaha Recommend 20W-50 or 10W-40 API SG or higher. Check manual for precise specification.

Brake Fluid Type:

DOT 4

Fork Oil Grade Xv535:

Yamaha Fork Oil 10W or equivalent

Fork Oil Grade Xv1100:

Yamaha Fork Oil 10W or equivalent

Carburetor Tuning:

Carburetors can become out of sync or clogged over time, requiring cleaning and adjustment. Diaphragms can also degrade.

Electrical Connections:

Corrosion in electrical connectors and switches is a common issue on older motorcycles, potentially leading to intermittent faults.

Fuel Lines:

Rubber fuel lines can degrade over time and should be inspected and replaced periodically.

Shaft Drive Maintenance:

Regular lubrication of the final drive shaft and U-joint is crucial to prevent premature wear.

📚 Vehicle History

Yamaha Motorcycles:

Yamaha has a long history of innovation in motorcycle design, from sportbikes to cruisers, with a reputation for reliability and performance.

Virago Line:

The Virago line was introduced to compete in the growing cruiser market. The XV535 served as a more accessible entry-level cruiser, while the XV1100 offered a larger displacement and more traditional cruiser experience.

Production Period:

The XV535 and XV1100 were produced for an extended period, indicating their popularity and robust design. The manual covers a significant span of this production run.

🏆 Awards & Recognition

Model Reputation:

The Virago line was well-regarded for its style, comfortable riding position, and reliable V-twin engines, making them popular choices for cruising and touring.