Target Audience:
Yamaha XV535 Virago owners, independent motorcycle mechanics, and DIY enthusiasts.
Value Proposition:
Offers a complete and authoritative guide for maintaining, diagnosing, and repairing the Yamaha XV535 Virago, empowering owners to perform tasks themselves and saving on dealership service costs.
Comparison To Alternatives:
This manual surpasses generic Haynes or Clymer manuals in depth and detail for the XV535 Virago, providing factory-level information for critical systems.
Content Emphasis:
Step-by-step instructions, clear diagrams, comprehensive troubleshooting guides, and detailed specifications.
Usability:
Designed for ease of use with logical organization and clear language.
Supported Years:
1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003
Regions Covered:
Global (specifications may vary slightly by market)
Estimated Page Count:
400+
Type:
Service Repair Manual
Engine Mechanical:
Complete teardown, inspection, repair, and assembly of engine components including cylinders, pistons, rings, crankshaft, connecting rods, valves, camshafts, timing system, lubrication system.
Fuel System:
Carburetor disassembly, cleaning, adjustment, synchronization; fuel pump operation; fuel tank and lines inspection.
Ignition System:
CDI system, spark plugs, ignition timing adjustment, troubleshooting of ignition faults.
Transmission Drivetrain:
Clutch inspection and replacement, gearbox disassembly and reassembly, final drive (shaft drive) maintenance, U-joint inspection.
Electrical System:
Wiring diagrams for all circuits, battery maintenance, charging system (stator, rectifier/regulator), lighting systems, starter motor, fuses, relays, switches, instrument cluster troubleshooting.
Suspension Steering:
Front fork service (oil change, seal replacement), rear shock absorber inspection and replacement, steering head bearing adjustment and replacement, wheel bearing maintenance.
Braking System:
Front and rear brake caliper service, brake pad replacement, brake fluid bleeding and replacement, master cylinder inspection, brake line inspection.
Cooling System:
Air-cooling system inspection, cylinder head fin cleaning.
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement.
Frame Chassis:
Frame inspection for damage, subframe mounting points.
Bodywork Fittings:
Fuel tank removal and installation, seat removal, fender inspection, minor body panel adjustments.
Maintenance:
Oil and filter changes, air filter cleaning/replacement, spark plug replacement, chain adjustment (if applicable, though Virago is shaft drive), brake fluid flush, coolant check (N/A for air-cooled), tire pressure checks, general lubrication.
Troubleshooting:
Diagnostic procedures for common starting issues, running problems, electrical faults, braking system anomalies.
Repair Overhaul:
Complete engine rebuilds, transmission overhauls, carburetor rebuilds, suspension fork rebuilds, brake caliper rebuilds.
Adjustments:
Carburetor synchronization, idle speed adjustment, clutch cable adjustment, steering head bearing adjustment, brake lever adjustment.
Component Replacement:
Detailed instructions for replacing parts such as brake pads, spark plugs, oil filters, fork seals, drive shafts, starter motors, batteries.
Depth:
Comprehensive from basic routine maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and specifications.
Diagrams:
Includes exploded views for most assemblies, wiring diagrams, and schematics.
Specifications Data:
Provides detailed torque specifications, clearance measurements, fluid capacities, and electrical component data.
Engine Type:
Air-cooled, 4-stroke, V-twin
Bore X Stroke:
76.0 mm x 58.0 mm
Valve Train:
SOHC, 2 valves per cylinder
Carburetion:
Dual Mikuni BS26SS (constant velocity carburetors)
Horsepower:
Approx. 40-45 hp @ 7500 rpm (market dependent)
Torque:
Approx. 4.5 kg-m (44 Nm) @ 5500 rpm (market dependent)
Fuel Tank Capacity:
9.0 Liters (2.4 US gal)
Fuel Type:
Unleaded gasoline, minimum 86 octane
Oil Capacity:
2.0 Liters (2.1 US qt) without filter change; 2.2 Liters (2.3 US qt) with filter change.
Recommended Oil Grade:
Yamalube 4 (or equivalent) SAE 20W-40, SAE 10W-40, or SAE 10W-30 based on ambient temperature (refer to manual for precise chart).
Spark Plug Type:
NGK DPR7EA-9 (or equivalent, confirm with manual)
Spark Plug Gap:
0.8 - 0.9 mm (0.032 - 0.035 in)
Engine Oil Change:
Every 3,000 km (2,000 miles) or 6 months, whichever comes first.
Oil Filter Change:
At every engine oil change.
Air Filter Cleaning:
Every 6,000 km (4,000 miles) or 12 months. Replace if damaged.
Spark Plug Inspection Replacement:
Inspect every 6,000 km (4,000 miles); replace as needed.
Brake Fluid Replacement:
Every 2 years or as per manual recommendation.
Clutch Adjustment:
Check and adjust every 6,000 km (4,000 miles).
Final Drive Oil Change:
Every 12,000 km (8,000 miles) or 12 months.
Engine Oil:
Yamalube 4 (or equivalent) SAE 20W-40, SAE 10W-40, or SAE 10W-30
Transmission Oil:
Yamalube 4 (or equivalent) SAE 80W GL-4 hypoid gear oil
Brake Fluid:
DOT 3 or DOT 4 hydraulic brake fluid
Carburetor Issues:
Can suffer from sticky slides or needle jet wear leading to poor performance and idle issues, especially with age and ethanol fuels. Regular cleaning and synchronization are key.
Electrical Connectors:
Corrosion or looseness in electrical connectors can lead to intermittent issues, especially around the ignition and lighting systems.
Shaft Drive Maintenance:
Requires regular lubrication of the final drive gears and universal joint to prevent wear. Rear differential seals can sometimes weep.
Fork Seals:
Front fork seals can degrade over time and leak, requiring replacement. This is a common maintenance item for most motorcycles of this age.
Fuel Line Degradation:
Older rubber fuel lines can become brittle and leak, especially when exposed to modern ethanol-laced fuels. Replacement with quality fuel-rated hoses is recommended.
