Target Audience:
Owners, independent repair shops, and vintage motorcycle enthusiasts seeking to maintain or restore their 1996 Yamaha Virago XV535.
Value Proposition:
Essential tool for accurate parts sourcing, efficient repair, and preserving the originality of the XV535 model.
Illustrated Diagrams:
The primary strength is its illustrated exploded diagrams, which are invaluable for visual learners and complex assemblies.
Part Number Listing:
Systematic listing of all OEM part numbers, ensuring correct and authentic replacements.
Engine Assembly:
Complete breakdown of engine components, including cylinder head, cylinders, pistons, crankshaft, camshafts, valve train, and lubrication system.
Fuel System:
Carburetor assembly (Mikuni VM series), fuel tank, fuel filter, fuel lines, and fuel pump (if applicable).
Transmission Drivetrain:
Gearbox components, clutch assembly, final drive (shaft drive), rear wheel hub and spokes.
Chassis Frame:
Frame components, steering head, swingarm, and mounting hardware.
Suspension:
Front fork assembly (including internals like springs, dampers, seals), rear shock absorbers, and mounting points.
Braking System:
Front and rear brake calipers, master cylinders, brake lines, brake discs, brake pads, and control levers.
Electrical System:
Ignition system components (CDI unit, spark plugs, coils), lighting (headlight, taillight, turn signals), battery, wiring harnesses, starter motor, and charging system (generator/alternator, regulator/rectifier).
Exhaust System:
Exhaust pipes, mufflers, heat shields, and mounting hardware.
Bodywork Fittings:
Fuel tank, fenders, side covers, seat, handlebars, control cables, mirrors, and badges.
Wheels Tires:
Wheel rims, spokes, hubs, tires, and tubes (if applicable).
Part Identification:
Detailed exploded views allowing precise identification of all original Yamaha part numbers for seamless ordering and replacement.
Disassembly Guidance:
Visual aids (exploded diagrams) crucial for understanding the correct order of disassembly for various components.
Assembly Reference:
Essential for reassembling components correctly after repair or replacement, ensuring proper fitment and function.
Completeness:
Highly comprehensive, detailing every fastener, washer, gasket, and component within the specified systems.
Diagram Detail:
High-resolution exploded diagrams providing clear visual reference for part relationships and mounting points.
Part Number Accuracy:
Provides OEM part numbers, critical for ensuring genuine Yamaha replacements and compatibility.
Digital Format Likelihood:
Likely provided as a digital format (PDF) for easy searching and printing of specific pages.
Diagram Clarity:
Designed for clarity in print, ensuring legibility of part numbers and assembly details.
Physical Format Consideration:
If printed, likely spiral-bound or comb-bound for lay-flat usability in a workshop environment.
Physical Format Consideration:
If printed, typically on durable paper stock to withstand workshop conditions.
Engine Type:
Air-cooled, V-twin, 4-stroke
Bore X Stroke:
76.0 mm x 58.0 mm
Valve Configuration:
SOHC, 2 valves per cylinder
Horsepower:
Approx. 45 HP @ 7500 RPM (Estimate, actual may vary)
Torque:
Approx. 44 Nm @ 6000 RPM (Estimate, actual may vary)
Carburetor Type:
Dual Mikuni VM34SS
Fuel Delivery:
Carbureted
Oil Type:
Yamaha Recommend: Yamalube 4 (SAE 20W-40) or equivalent API SE, SF, SG type motorcycle oil.
Oil Capacity:
Approx. 2.4 Liters (with filter change)
Oil Change Interval:
Recommended every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first. Specifics detailed in a full service manual.
Spark Plug Replacement:
Typically around 10,000-15,000 km (6,000-9,000 miles). Specific plug type and gap detailed in service manual.
Valve Clearance Check:
Recommended interval typically around 10,000-20,000 km (6,000-12,000 miles), depending on severity of use. Critical for engine performance and longevity.
Brake Fluid:
DOT 4 recommended for hydraulic systems.
Fork Oil:
Yamalube Fork Oil 10W or equivalent, capacity specified per fork leg in service manual.
Carburetor Synchronization:
Carburetors can fall out of sync over time, leading to rough idling or poor throttle response. The parts manual helps identify all components for potential cleaning or adjustment.
Shaft Drive Maintenance:
Regular lubrication of the shaft drive spline is crucial to prevent wear and seizing. The parts manual will list the specific grease and sealing components.
Electrical Connections:
Corrosion or loose connections in wiring harnesses can lead to intermittent electrical faults. The manual aids in tracing and identifying specific connectors and wires.
Yamaha Motorcycles:
Yamaha Motor Company is renowned for its innovation, performance, and quality across a wide range of motorized products, including a strong legacy in motorcycle manufacturing.
Virago Lineage:
The Virago line, introduced in the early 1980s, established Yamaha as a major player in the cruiser motorcycle market, known for its V-twin engines and distinctive styling. The XV535 was a popular mid-size offering within this line.
Xv535 Production Years:
The XV535 model was produced across various markets from the mid-1980s through the early 2000s, with the 1996 model being a representative example of its mature design.
