Segment:
Cruiser Motorcycle
Target Audience:
Owners of 1987-1994 Yamaha XV535 Virago, independent motorcycle mechanics, restoration enthusiasts
Key Competitors Model Years:
Honda Shadow 500/600, Kawasaki Vulcan 500, Suzuki Intruder 400/750 (during its production era)
Design Philosophy:
Classic V-twin cruiser styling, accessible performance and comfort
Manual Value Proposition:
Provides factory-level technical data for accurate maintenance and repair, ensuring optimal performance and longevity.
Manufacture Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994
Geographic Coverage:
Global (primarily focused on models sold in major markets)
Estimated Page Count:
300-500 pages (typical for comprehensive factory service manuals)
Type:
Factory Service Manual (FSM) / Repair Manual
Format:
Downloadable Digital Format (PDF)
Engine:
Complete engine disassembly, assembly, tuning, lubrication, cooling, ignition, fuel delivery
Transmission:
Clutch operation, gear shifting mechanisms, transmission disassembly and assembly
Chassis:
Frame inspection, front fork service, rear suspension, steering system, wheel bearings
Brakes:
Front and rear brake system inspection, service, fluid replacement, caliper maintenance
Electrical System:
Wiring diagrams, charging system, starting system, lighting, ignition system, instrumentation
Fuel System:
Carburetor overhaul and adjustment, fuel tank, fuel lines, fuel pump (if applicable)
Body And Trim:
Fairings, body panels, seat, fuel tank removal and installation, emblems
Cooling System:
Air cooling system analysis and maintenance
Maintenance:
Routine checks, lubrication intervals, filter replacements, spark plug service
Troubleshooting:
Diagnostic charts for common problems and their solutions
Repair:
Step-by-step instructions for component repair and replacement
Rebuild:
Detailed procedures for engine and transmission overhauls
Adjustment:
Carburetor synchronization, valve clearance adjustment, brake lever adjustment
Inspection:
Component wear inspection, safety checks, torque value specifications
Depth:
Comprehensive from basic maintenance to complete engine rebuilds and electrical system diagnostics
Diagnostic Capability:
Detailed troubleshooting guides and flowcharts
Specifications:
Includes all necessary torque specifications, clearances, and fluid capacities
Engine Type:
Air-cooled, four-stroke, V-twin
Bore X Stroke:
73.0 mm x 63.8 mm
Compression Ratio:
9.7:1 (typical)
Valve Train:
SOHC, 2 valves per cylinder
Power Delivery:
Smooth, torquey delivery suitable for cruising
Horsepower Range:
Approximately 40-45 HP (at crankshaft, model year dependent)
Torque Range:
Approximately 40-45 Nm (at crankshaft, model year dependent)
Carburetor:
Dual Mikuni carburetors (e.g., Mikuni BS34)
Fuel Capacity:
Approx. 14.0 Liters (3.7 US gal)
Fuel Type:
Unleaded gasoline (Octane rating specified in manual, typically 87 or higher)
Overall Length:
Approx. 2,235 mm (88.0 in)
Overall Width:
Approx. 785 mm (30.9 in)
Overall Height:
Approx. 1,105 mm (43.5 in)
Wheelbase:
Approx. 1,520 mm (59.8 in)
Dry Weight:
Approx. 170 kg (375 lbs)
Wet Weight:
Approx. 183 kg (403 lbs)
Max Load:
Refer to manual for specific payload capacity
Safety Ratings:
N/A (Motorcycle safety is primarily determined by rider skill and adherence to traffic laws)
Braking System:
Disc front brake, Drum rear brake (standard on most models; some later variants may have disc rear).
Lighting:
Halogen headlight, taillight, brake light, turn signals
Mirrors:
Adjustable rearview mirrors
Infotainment System:
N/A (Mechanical motorcycle with analog instrumentation)
Dashboard:
Analog speedometer, tachometer, fuel gauge, indicator lights for turn signals, high beam, oil pressure.
Oil Change:
Every 5,000 km (3,000 miles) or 6 months (refer to manual for exact interval)
Air Filter Cleaning:
Every 5,000 km (3,000 miles) or as needed based on riding conditions
Spark Plug Replacement:
Every 10,000 km (6,000 miles) (refer to manual for specific spark plug type and gap)
Valve Clearance Check:
Every 10,000 km (6,000 miles) (critical for performance and engine longevity)
Engine Oil Type:
Yamalube 4 (or equivalent SAE 20W-40, API SE, SF, SG or higher)
Engine Oil Capacity:
Approx. 2.1 Liters (2.2 US qt) without filter change, 2.4 Liters (2.5 US qt) with filter change.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid
Final Drive Oil Type:
Yamalube Hypoid Gear Oil (or equivalent SAE 80W-90)
Carburetor Issues:
Carburetor icing in cold weather, jet clogging due to fuel degradation over time.
Electrical Gremlins:
Corrosion on electrical connectors, aging wiring harnesses can lead to intermittent issues.
Clutch Wear:
Clutch plates may require replacement after prolonged use or aggressive riding.
Cam Chain Tensioner:
Some models may benefit from an upgraded cam chain tensioner for increased reliability.
Yamaha Motorcycles:
Yamaha Motor Company has a long history in motorcycle manufacturing, known for innovation and performance across various categories.
Virago Lineage:
The Virago line was Yamaha's entry into the V-twin cruiser market, offering accessible styling and technology. The XV535 was a popular mid-displacement model.
Production Period:
1987-2004 (XV535 model, with variations and updates throughout)
Manufacturing Location:
Japan