Positioning:
The Yamaha Virago XV535 was positioned as an entry-level to mid-range cruiser, known for its V-twin engine, shaft drive, and distinctive styling, appealing to riders seeking classic cruiser aesthetics with reliable Japanese engineering.
Competitors:
Competed with models like the Honda Shadow 600, Kawasaki Vulcan 500, and Suzuki Intruder 700/750 in its segment.
Features:
534cc V-twin engine, 5-speed transmission, shaft drive, classic cruiser styling, comfortable riding position, user-friendly operation.
Engine:
Engine Overhaul, Cylinder Head, Piston, Crankshaft, Lubrication System, Cooling System (Air-Cooled)
Fuel System:
Carburetor, Fuel Tank, Fuel Lines, Fuel Pump
Transmission:
Clutch, Gearbox, Drive Shaft, Final Drive (Shaft Drive)
Electrical System:
Ignition System, Charging System, Lighting, Starter Motor, Battery, Wiring Diagrams
Suspension:
Front Forks, Rear Shock Absorbers, Swingarm
Brakes:
Front and Rear Brake Systems (Hydraulic Disc Front, Drum Rear), Brake Lines, Calipers, Master Cylinders
Frame And Bodywork:
Frame, Fuel Tank, Seat, Fenders, Handlebars, Controls
Maintenance:
Routine Inspections, Oil Changes, Filter Replacements, Spark Plug Replacement, Carburetor Cleaning and Adjustment
Repair:
Engine Rebuilds, Transmission Repairs, Brake System Servicing, Electrical Component Replacement, Suspension Overhaul
Troubleshooting:
Diagnostic Procedures for Engine, Electrical, and Mechanical Issues
Carburetor Rebuild:
Detailed instructions for disassembly, cleaning, inspection, reassembly, and adjustment of the dual Mikuni carburetors.
Ignition Timing Adjustment:
Procedures for checking and adjusting ignition timing.
Clutch Adjustment:
Specifications and procedures for clutch lever play adjustment and clutch component service.
Wheel Bearing Service:
Instructions for wheel removal, bearing inspection, replacement, and proper installation.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all systems, aiding in diagnosis and repair of electrical faults.
Depth:
Comprehensive workshop-level detail including disassembly, assembly, adjustments, specifications, and torque values.
Specifications:
Includes detailed torque specifications for all fasteners, measurement tolerances, and component clearances.
Diagnostic Charts:
Troubleshooting charts to help identify and resolve common problems systematically.
File Format:
PDF (Portable Document Format)
Searchability:
PDF format allows for keyword searching for quick access to specific information.
Print Quality:
High-resolution scans suitable for printing or on-screen viewing.
Page Layout:
Clear page layout with diagrams, illustrations, and text organized logically.
Binding Type:
Digital Download (No physical binding)
Paper Type:
N/A (Digital)
Engine Type:
Air-cooled, 70-degree V-twin, 4-stroke
Bore X Stroke:
76.0 mm x 58.0 mm
Valve Train:
SOHC, 2 valves per cylinder
Horsepower:
Approx. 46 hp @ 7500 rpm (Manufacturer Claim)
Torque:
Approx. 46 Nm (34 lb-ft) @ 6000 rpm (Manufacturer Claim)
Carburetor:
Dual Mikuni BS32 carburetors
Fuel Capacity:
13 Liters (3.4 US gal)
Oil Type:
API SE, SF, SG, SH or higher, SAE 20W-40 (Recommended)
Oil Capacity:
2.4 Liters (2.5 US qt) without filter change, 2.6 Liters (2.7 US qt) with filter change.
Cooling Method:
Air-cooled
Oil Change Interval:
Every 4,000 km (2,500 miles) or 6 months, whichever comes first.
Air Filter Cleaning:
Every 4,000 km (2,500 miles).
Spark Plug Replacement:
Every 8,000 km (5,000 miles).
Valve Clearance Check:
Every 8,000 km (5,000 miles) or annually.
Drive Shaft Grease:
Recommended periodic lubrication of drive shaft splines as per manual instructions.
Brake Fluid:
DOT 3 or DOT 4 (Refer to manual for specific type)
Final Drive Oil:
Yamaha Hypoid Gear Oil SAE 80 or equivalent API GL-4 (Refer to manual for specific type and capacity)
Known Issues:
Carburetor tuning can be sensitive; potential for cam chain noise; rear brake master cylinder seals can degrade over time; shaft drive splines may require periodic greasing.
Brand Heritage:
Yamaha Motor Company has a long and storied history in motorcycle manufacturing, known for innovation, performance, and reliability across various categories.
Model Evolution:
The Virago line, including the XV535, represented Yamaha's entry into the popular cruiser market, evolving from earlier models with a focus on classic styling and user-friendliness. Minor updates occurred throughout its production run.
Key Updates:
Minor cosmetic and component updates across the production years, but the core mechanicals remained largely consistent.
Production Period:
The XV535 was produced from the mid-1980s through the 1990s, with the specific years 1987-1994 covered by this manual.
