Category:
Entry-level cruiser motorcycle.
Target Audience:
New riders, custom enthusiasts, those seeking a reliable and stylish V-twin cruiser.
Competitors:
Honda Shadow series, Kawasaki Vulcan series, Suzuki Intruder series of the era.
Engine Configuration:
V-twin architecture for classic cruiser aesthetics and sound.
Styling:
Low-slung profile, teardrop fuel tank, pulled-back handlebars, chrome accents contributing to its 'Virago' identity.
Drivetrain:
Shaft drive for low maintenance compared to chain drives.
Years Covered:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994
Type:
Service Repair Workshop Manual
Engine:
Complete overhaul, diagnosis, tuning, carburetor service, lubrication system, cooling system (air-cooled specific details).
Fuel System:
Carburetor identification, disassembly, cleaning, adjustment, float bowl service, fuel pump operation, fuel tank maintenance.
Transmission Drivetrain:
Clutch operation, gear shift mechanism, final drive (shaft drive) inspection, maintenance, and repair.
Electrical System:
Ignition system (CDI), starting system, charging system (alternator, regulator/rectifier), lighting, instrumentation, wiring diagrams, battery maintenance.
Brakes:
Front and rear brake system service, hydraulic components, pad/shoe replacement, bleeding procedures, caliper maintenance.
Suspension Steering:
Front fork overhaul, seal replacement, oil levels, rear shock absorber service, steering head bearing adjustment.
Chassis Frame:
Frame inspection, swingarm pivot bearing service, wheel bearing maintenance.
Bodywork Trim:
Body panel removal and installation, seat, fuel tank, fenders, minor cosmetic repairs.
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points, chain adjustment (if applicable to final drive).
Troubleshooting:
Diagnostic charts for common performance issues, electrical faults, starting problems, and running irregularities.
Repair:
Detailed step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.
Specifications:
Torque specifications for all fasteners, critical measurements, clearances, and tolerances.
Level:
Comprehensive workshop-level repair, including engine rebuilds and complex electrical diagnostics.
Readability:
High-resolution scans for clear text and diagrams.
Searchability:
Likely searchable PDF text (depending on scan quality).
Clarity:
Designed for clear reproduction if printed.
Format Note:
Digital format, printable pages.
Format Note:
N/A (Digital).
Engine Type:
4-stroke, air-cooled, V-twin, SOHC, 2 valves per cylinder.
Displacement:
534 cc (32.5 cu in)
Bore X Stroke:
76.0 mm x 58.0 mm (3.0 in x 2.3 in)
Horsepower Est:
Approximately 46-48 HP (specific dyno figures may vary).
Torque Est:
Approximately 42-44 lb-ft (specific dyno figures may vary).
Carburetor:
Dual Mikuni BS32 carburetors (or similar Mikuni configuration).
Fuel Capacity:
Approx. 13.0 L (3.4 US gal)
Safety Features:
Standard motorcycle safety features for its era; no specific crash ratings typically apply.
Brakes:
Disc front brake, drum rear brake (depending on market variant, some may have dual discs or rear drum).
Lighting:
Halogen headlight, LED taillight (later models), turn signals.
Features:
Basic analog instrumentation: speedometer, tachometer (on some variants), fuel gauge, odometer, trip meter, indicator lights.
Features:
N/A (No modern driver assistance systems).
Features:
N/A (No connectivity features).
Oil Change:
Every 3,000 - 5,000 km (1,800 - 3,000 miles) or annually, check manual for specific interval.
Spark Plug Replacement:
Typically every 10,000 - 15,000 km (6,000 - 9,000 miles).
Valve Clearance Check:
Every 10,000 - 20,000 km (6,000 - 12,000 miles), critical for smooth V-twin operation.
Engine Oil:
Yamalube 4 (or equivalent API SG or higher) SAE 10W-40 or 20W-40 motorcycle oil. Consult manual for precise viscosity based on temperature.
Brake Fluid:
DOT 3 or DOT 4 brake fluid.
Fork Oil:
Yamaha 5W or equivalent. Specific volume per fork leg to be confirmed in manual.
Coolant:
N/A (Air-cooled engine).
Carburetor Sync:
Carburetors can drift out of sync, requiring periodic synchronization for optimal performance and fuel economy.
Electrical Connections:
Corrosion on electrical connectors can lead to intermittent issues, particularly in humid or salty environments.
Charging System:
Regulator/rectifier units can be a point of failure over time, leading to battery charging problems.
Fuel Tank Corrosion:
Some early models may experience internal fuel tank corrosion if left with fuel for extended periods without stabilizers or proper storage.
Manufacturer:
Yamaha Motor Company, known for its extensive history in motorcycle manufacturing and innovation.
Generation:
The XV535 Virago was part of Yamaha's Virago line, introduced to offer a smaller, more accessible cruiser alternative to larger displacement models like the XV750 and XV1100.
Production Span:
The XV535 was produced from the mid-1980s through the early 2000s, with this manual covering the 1987-1994 period which represents early to mid-production models.
