🏷️ Basic Information

Make:

Yamaha

Model:

XV535 Virago

Product Name:

Yamaha XV535 Virago 1987-2003 Workshop Service Repair Manual

Model Code Range:

XV535

👋 Introduction

Market Position:

The Yamaha XV535 Virago was a popular mid-size cruiser, known for its classic styling and V-twin engine, appealing to riders seeking an accessible and stylish cruiser experience.

Competitors:

Competed with models like the Honda Shadow series, Kawasaki Vulcan series, and Suzuki Intruder series in the mid-size cruiser segment.

Key Features:

V-twin engine, shaft drive, comfortable riding position, classic cruiser aesthetics, accessible for riders of various experience levels.

📋 Manual Details

Applicable Years:

1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003

Page Count:

438

Manual Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF

📖 Manual Coverage

Engine Mechanical:

Detailed overhaul procedures for cylinder head, cylinders, pistons, crankshaft, camshafts, valve train, lubrication system.

Fuel System:

Carburetor overhaul, adjustment, fuel pump inspection, fuel tank maintenance, fuel line routing.

Ignition System:

CDI unit, ignition coils, spark plug specifications, timing procedures, troubleshooting.

Transmission Drivetrain:

Gearbox disassembly and assembly, clutch operation, final drive maintenance, shaft and bearing inspection.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor, ignition switch troubleshooting.

Braking System:

Front and rear brake caliper overhaul, master cylinder inspection, brake fluid replacement, bleeding procedures, disc and pad specifications.

Suspension Steering:

Front fork disassembly, seal replacement, oil type and level, rear shock absorber adjustment and replacement, steering head bearing maintenance.

Chassis Frame:

Frame inspection, swingarm maintenance, wheel bearing replacement, spoke tensioning (if applicable).

Bodywork Fittings:

Body panel removal and installation, seat, fuel tank, fender, and exhaust system service.

Routine Maintenance:

Oil changes, filter replacements, spark plug inspection/replacement, chain adjustment, brake adjustments, lubrication points.

Troubleshooting:

Diagnostic flowcharts for common running problems, electrical faults, and starting issues.

Engine Rebuild:

Complete step-by-step instructions for engine disassembly, inspection, repair, and reassembly, including torque specifications.

Carburetor Tuning:

Detailed instructions for cleaning, rebuilding, and synchronizing carburetors for optimal performance.

Electrical Diagnostics:

Guidance on using multimeters, tracing electrical faults, and testing components.

Brake System Service:

Complete guide to brake fluid flushes, caliper rebuilds, and master cylinder servicing.

Suspension Overhaul:

Detailed instructions for front fork and rear shock absorber maintenance.

Wheel And Tire Service:

Instructions for wheel balancing, tire mounting, and bearing replacement.

Depth:

Comprehensive, covering from basic maintenance to complete engine and gearbox rebuilds, including detailed troubleshooting guides.

📊 Manual Specifications

File Format:

Digital PDF

Print Quality:

High-resolution, designed for clarity when printed or viewed on screen.

Binding Type:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

Searchability:

Searchable text within the PDF document for quick access to information.

Illustrations:

Includes detailed diagrams, schematics, and exploded views to aid in repair and identification.

⚙️ Engine Specifications

Engine Type:

Air-cooled, 4-stroke, V-twin

Displacement:

534cc

Bore X Stroke:

76.0 mm x 58.0 mm

Valvetrain:

SOHC, 2 valves per cylinder

Compression Ratio:

9.7:1

Maximum Power:

Approx. 45-48 HP (depending on market and tuning)

Maximum Torque:

Approx. 44 Nm (depending on market and tuning)

Carburetion:

Dual Mikuni BS32 carburetors

Fuel Capacity:

14.0 Liters (3.7 US gal)

Fuel Type:

Unleaded gasoline

🔧 Transmission

Transmission Type:

5-speed constant mesh

Final Drive:

Shaft drive

Clutch Type:

Wet, multiple-disc

📐 Dimensions

Length:

2230 mm (87.8 in)

Width:

810 mm (31.9 in)

Height:

1105 mm (43.5 in)

Wheelbase:

1520 mm (59.8 in)

Ground Clearance:

150 mm (5.9 in)

Dry Weight:

181 kg (399 lbs)

Wet Weight:

Approx. 200 kg (441 lbs) with fluids

Seat Height:

725 mm (28.5 in)

🛡️ Safety Features

Safety Ratings:

Motorcycles are not typically rated by organizations like NHTSA or Euro NCAP; safety relies on rider skill and adherence to maintenance.

Active Safety:

Disc brakes, responsive suspension, good rider visibility.

Passive Safety:

Sturdy frame construction, handlebar design for control.

💡 Technology Features

Infotainment Features:

Basic motorcycle instrumentation: speedometer, tachometer, odometer, trip meter, neutral indicator, turn signal indicators, oil pressure warning light.

Driver Assistance Features:

N/A (Standard motorcycle features).

Connectivity Features:

N/A (Standard motorcycle features).

🔧 Maintenance

Oil Change Interval:

Every 3,000-5,000 km (1,800-3,000 miles) or 6 months, whichever comes first.

Valve Clearance Check:

Every 10,000-15,000 km (6,000-9,000 miles).

Spark Plug Replacement:

Every 10,000-15,000 km (6,000-9,000 miles).

Air Filter Cleaning:

Regular inspection and cleaning every 5,000 km (3,000 miles); replacement as needed.

Engine Oil Type:

Yamalube 4 (or equivalent) SAE 20W-40 or 20W-50 API service SE, SF, SG or SH

Engine Oil Capacity:

2.4 Liters (2.5 US qt) with filter change

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid

Fork Oil Type:

Yamaha Fork Oil 10W or equivalent

Fork Oil Capacity:

300 ml (0.30 L or 10.1 US oz) per fork leg

Known Issues:

Potential issues include carburetor clogging due to infrequent use, fork seal leaks, and stator/rectifier failures. The exhaust pipes can also be prone to rust. Regular maintenance, especially fuel system care and electrical checks, is crucial.

📚 Vehicle History

Brand Heritage:

Yamaha Motor Company, founded in 1955, has a rich history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments.

Model Evolution:

The XV535 Virago was introduced in 1987 as part of Yamaha's Virago line of V-twin cruisers. It was designed as a more accessible and stylish option compared to larger cruisers, featuring a lower seat height and classic styling. Minor updates occurred throughout its production run, but the core design remained consistent.

Production Years:

1987-2003

Manufacturing Locations:

Primarily manufactured in Japan, with potential assembly in other Yamaha facilities globally.

🏆 Awards & Recognition

Recognitions:

The XV535 Virago was a consistent seller and well-regarded within its segment for its balance of style, performance, and affordability, though specific industry awards are not prominently documented.