Production Years Covered:
1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Engine Code Prefix:
XV535E
Motorcycle Segment:
Cruiser motorcycle.
Target Audience For Manual:
Yamaha XV535 Virago owners requiring in-depth maintenance and repair information.
Typical Competitors:
Honda Shadow VT, Kawasaki Vulcan VN series, Suzuki Intruder VS series.
Styling:
Classic V-twin cruiser styling with chrome accents.
Drivetrain:
Shaft drive for low maintenance.
Engine Configuration:
V-twin engine, known for its torque and sound.
Engine System:
Detailed coverage of engine disassembly, assembly, inspection, and troubleshooting.
Fuel System:
Carburetor system, fuel pump, fuel lines, and fuel tank servicing.
Ignition System:
Ignition timing, spark plugs, ignition coils, and CDI unit diagnostics.
Transmission System:
Gearbox operation, clutch service, shift mechanism, and lubrication.
Drivetrain System:
Shaft drive system, universal joints, final drive assembly.
Suspension System:
Front fork service (seals, oil, springs), rear shock absorber replacement, swingarm maintenance.
Braking System:
Front and rear brake caliper service, master cylinder overhaul, brake fluid replacement, pad/shoe replacement.
Electrical System:
Wiring diagrams, lighting, starting system, charging system (stator, regulator/rectifier), battery maintenance.
Cooling System:
Air-cooled engine specifics, oil cooler service.
Exhaust System:
Muffler and pipe inspection, gasket replacement.
Frame And Bodywork:
Frame inspection, body panel removal and installation, seat, handlebars, and controls.
Routine Maintenance:
Oil changes, filter replacements, chain adjustment (if applicable, though XV535 is shaft drive), tire pressure checks.
Troubleshooting:
Diagnostic charts and symptom-based problem-solving for various systems.
Engine Rebuild:
Complete engine overhaul procedures, including piston, ring, and cylinder head service.
Component Overhaul:
Detailed instructions for overhauling carburetors, brake components, and electrical parts.
Inspections:
Scheduled inspections for wear and tear, safety checks.
Adjustments:
Carburetor synchronization, clutch lever adjustment, throttle cable adjustment.
Technical Depth Level:
In-depth diagnostic and repair procedures suitable for professional mechanics and experienced DIY enthusiasts.
Service Manual Completeness:
Covers all aspects from routine maintenance to complete engine and chassis rebuilds.
Engine Type:
Air-cooled, 4-stroke, V-twin
Displacement:
535 cc (32.6 cubic inches)
Bore X Stroke:
76.0 mm x 58.0 mm
Valve Train:
SOHC, 2 valves per cylinder
Cooling Method:
Air-cooled
Horsepower Approx:
Approx. 40-45 HP (exact figures vary by market and tuning)
Torque Approx:
Approx. 4.3 kg-m (31.1 ft-lbs) at around 6,000 RPM
Fuel Delivery:
Dual Mikuni B27 carburetors (e.g., VM27 x 2)
Fuel Tank Capacity:
Approx. 14 liters (3.7 US gal)
Oil Type:
Yamalube 4-stroke motorcycle oil, API SG or higher, SAE 10W-40 recommended.
Overall Length:
Approx. 2,265 mm (89.2 in)
Overall Width:
Approx. 780 mm (30.7 in)
Overall Height:
Approx. 1,135 mm (44.7 in)
Wheelbase:
Approx. 1,520 mm (59.8 in)
Dry Weight:
Approx. 178 kg (392 lbs)
Wet Weight:
Approx. 194 kg (428 lbs) (with all fluids)
Maximum Load:
Refer to manual for specific load capacity and rider weight limits.
Safety Certification:
Meets relevant national and international motorcycle safety standards for its era.
Braking System Type:
Front: Disc brake; Rear: Drum brake.
Tire Sizes Recommended:
Front: 100/90-19; Rear: 130/90-15 (specific tire models and load ratings should be consulted).
Lighting System:
Halogen headlamp, tail/brake light, turn signals.
Engine Oil Change Interval:
Every 3,000 km (1,800 miles) or 6 months, whichever comes first.
Oil Filter Replacement Interval:
Replace at every oil change (refer to manual for specific part numbers).
Spark Plug Replacement Interval:
Inspect every 6,000 km (3,600 miles), replace as needed. (Specific plug type detailed in manual).
Air Filter Cleaning Interval:
Inspect and clean every 6,000 km (3,600 miles), replace as needed.
Shaft Drive Oil Change Interval:
Every 12,000 km (7,200 miles) or 12 months.
Brake Fluid Change Interval:
Every 12,000 km (7,200 miles) or 12 months, or as needed if contamination is suspected.
Engine Oil Specification:
Yamalube 4-stroke motorcycle oil, API SG or higher, SAE 10W-40.
Transmission Oil Specification:
Yamaha Gear Oil SAE 80W API GL-4.
Brake Fluid Specification:
DOT 4 hydraulic brake fluid.
Fork Oil Specification:
Specific viscosity and volume detailed in manual (typically a 10W fork oil).
Common Wear Items:
Clutch plates, fork seals, exhaust gaskets, carburetor diaphragms.
Potential Electrical Issues:
Aging wiring harnesses, regulator/rectifier failures can be common on older bikes.
Carburetor Maintenance:
Requires periodic cleaning and synchronization due to age and potential fuel deposits.
Manufacturer:
Yamaha Motor Company, a Japanese manufacturer with a long history in motorcycle production.
Virago Lineage:
Part of Yamaha's Virago line, known for its V-twin engines and cruiser styling, introduced in the early 1980s.
Xv535 Introduction:
The XV535 was a popular middleweight cruiser, offering classic styling and accessible performance.
Production Period For Model:
Original production started in the mid-1980s and continued with updates through the early 2000s.
Manufacturing Locations:
Primarily Japan, with potential assembly in other regions depending on market.
Historical Reception:
Generally well-regarded as a reliable and stylish entry-level to mid-range cruiser of its era.
Motorcycle Reviews Consensus:
Praised for its comfortable riding position, V-twin character, and ease of maintenance (especially the shaft drive).
Manual Quality Certification:
This manual is a professional-grade workshop document, essential for accurate servicing.
