🏷️ Basic Information

Make:

Yamaha

Model:

XV535 Virago

Product Name:

Yamaha XV535 Virago Service Repair Manual

Engine Code:

4X7 (typical for XV535)

👋 Introduction

Segment:

Cruiser Motorcycle

Target Audience:

Owners, technicians, and enthusiasts performing maintenance and repairs on the Yamaha XV535 Virago

Rival Models:

Honda Shadow VT500/VT600, Kawasaki Vulcan 500, Suzuki Intruder VS700/VS750

Vehicle Appeal:

Classic cruiser styling, V-twin engine, comfortable riding position, reliable performance

Manual Value:

Essential for maintaining the longevity and optimal performance of the XV535 Virago

📋 Manual Details

Sections:

General Information, Periodic Maintenance, Fuel System (DFI), Cooling System, Engine Top End, Clutch, Engine Lubrication System, Engine Removal/Installation, Crankshaft/Transmission, Wheels/Tires, Final Drive, Brakes, Steering, Suspension, Frame, Electrical System, Troubleshooting

Estimated Pages:

200-300

Type:

Service Repair Manual

Language:

English

Format:

Digital (PDF)

📖 Manual Coverage

Powertrain:

Engine (top end, lubrication, removal/installation), Fuel System (DFI), Clutch, Transmission, Final Drive

Chassis:

Wheels/Tires, Brakes, Steering, Suspension, Frame

Electrical:

Wiring diagrams, ignition, lighting, starting/charging systems

Maintenance:

Periodic maintenance, fluid changes, lubrication, filter replacement, adjustments

Repair:

Engine rebuild, transmission overhaul, brake system repair, suspension component replacement, electrical component troubleshooting and repair

Diagnostics:

Troubleshooting guides for common issues, fault code interpretation (if applicable to DFI)

Scope:

Comprehensive, covering all aspects of service and repair for the XV535 Virago

Detail Level:

Detailed step-by-step instructions, torque specifications, special tool requirements, schematics

📊 Manual Specifications

PDF Quality:

High-resolution, searchable text for easy navigation and printing

Printability:

Designed for clear printing of all diagrams, text, and specifications

Binding:

Not applicable for digital format

Paper Type:

Not applicable for digital format

⚙️ Engine Specifications

Configuration:

V-twin, four-stroke

Displacement:

535 cc

Bore X Stroke:

76.0 mm x 58.0 mm (typical)

Compression Ratio:

9.5:1 (typical)

Horsepower:

Approximately 45 hp @ 7500 rpm (varies by year and market)

Torque:

Approximately 30 lb-ft @ 5500 rpm (varies by year and market)

Induction:

Digital Fuel Injection (DFI)

Throttle Body Size:

34 mm (typical)

Type:

Liquid-cooled

Type:

Wet sump

Configuration:

V-twin layout

🔧 Transmission

Type:

5-speed constant mesh

Clutch Type:

Wet, multi-plate

Gear Ratios:

Specific ratios detailed in manual

Transmission Oil:

Yamaha Genuine Gear Oil (or equivalent SAE 80 GL-4)

📐 Dimensions

Length:

Approx. 2290 mm (90.2 in)

Width:

Approx. 850 mm (33.5 in)

Height:

Approx. 1175 mm (46.3 in)

Dry Weight:

Approx. 170 kg (375 lbs)

Wet Weight:

Approx. 184 kg (406 lbs)

Fuel Capacity:

13 L (3.4 US gal)

🛡️ Safety Features

Crash Test Data:

Not applicable to motorcycles in the same way as cars; manual focuses on component safety and operational integrity

Braking System:

Front: Disc, Rear: Drum (typically)

Frame Construction:

Steel, double-cradle frame

💡 Technology Features

Features:

Not applicable; analog instrumentation typical for this era.

Features:

Not applicable.

Features:

Not applicable.

System:

Digital Fuel Injection (DFI) system for precise fuel metering and ignition timing.

🔧 Maintenance

Oil Change:

Every 4,000 km (2,500 miles) or 6 months

Spark Plug Replacement:

Every 10,000 km (6,000 miles)

Air Filter Cleaning/Replacement:

Every 5,000 km (3,000 miles)

Engine Oil Type:

Yamalube 4 (or equivalent SAE 20W-40 API SG or higher)

Engine Oil Capacity:

2.5 L (with oil filter change)

Coolant Type:

Yamaha All Weather Coolant (or equivalent ethylene glycol based coolant)

Brake Fluid Type:

DOT 4

Fuel System:

DFI system can be sensitive to contamination; potential for fuel pump issues on older models.

Electrical:

Aging wiring harnesses, rectifier/regulator failures, starter solenoid issues are possible on higher mileage units.

Engine:

Occasional carburetor issues (on non-DFI models, though this manual specifies DFI), valve seat wear on very high mileage engines.

Common Filters:

Oil Filter: 5H0-13440-00-00 (example, verify with exact VIN)

📚 Vehicle History

Yamaha Motorcycles:

Yamaha Motor Company, established in 1955, known for its innovation and performance in motorcycles, marine products, and audio equipment.

Virago Line:

The Virago line, launched in the early 1980s, represented Yamaha's entry into the custom cruiser market, offering stylish designs and V-twin engines. The XV535 was a popular mid-size offering.

Production Years:

1987 - 2004 (approximate, may vary by market)

Manufacturing Locations:

Japan

🏆 Awards & Recognition

Industry Awards:

While specific awards for the XV535 are not widely documented, the Virago line as a whole was recognized for its style and accessibility in the cruiser market of its time.