Yamaha Virago XV535M User manual

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OWNER'S MANUAL
LIT-1 1626-1 3-1
6
Virago
XV535M
XV535MC

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Dear New Yamaha ATV Owner:
CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV. You have purchased aquality
Yamaha product that, with proper use and care, will provide hours of riding pleasure. BEFORE YOU
OPERATE YOUR NEW ATV, Yamaha recommends these important points:
eREAD YOUR OWNER'S MANUAL >
•ACHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR I
GREATER _
•ACHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER ^
THAN 90CC LL
•TAKE THE FREE HANDS-ON TRAINING COURSE OFFERED BY YAMAHA -ASK YOUR DEALER FOR UJ
DETAILS OR CALL 1-800-887-2887 f£
If you have any questions about these points, or if you purchased your ATV from an authorized Yamaha
dealership and were not informed of the age recommendation for your ATV by the dealership, please
fill out the information below and mail this card to Yamaha today. ^i
Name: ATV Model: Purchase Date:
<
LMO. OAY
Address: Primary I.D (Engine Number):
Dealer Name &Address: LU
Telephone:
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BUSINESS REPLY MAIL
FIRST CLASS PERMIT NO. 4CYPRESS, CA
POSTAGE WILL BE PAID BY ADDRESSEE
YAMAHA MOTOR CORPORATION U.S.A.
P.O. BOX 6555
CYPRESS, CALIFORNIA 90630-9989
NO POSTAGE
NECESSARY
IF MAILED
IN THE
UNITED STATES
ATTN: SALES ADMINISTRATION
II.ImII.„,II„„II,II,„I.ImI.I„I„I,I,I„I„.II

INTRODUCTION
Congratulations on your purchase of the Yamaha XV535/XV535C. This model is the
result of Yamaha's vast experience in the production of fine sporting, touring, and pac-
esetting racing machines. It represents the high degree of craftsmanship and reliability
that have made Yamaha aleader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions about the operation or main-
tenance of your motorcycle, please consult aYamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the emis-
sions standards for clean air applicable at the date of manufacture. Yamaha has met
these standards without reducing the motorcycle's performance or economy of opera-
tion. To maintain these high standards, it is important that you and your dealer pay
close attention to the recommended maintenance schedules and operating instructions
contained within this manual.

IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
AThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY
IS INVOLVED!
AWARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, abystander or aperson inspecting or repairing the
motorcycle.
CAUTION: ACAUTION indicates special precautions that must be taken to avoid damage to
the motorcycle.
NOTE: ANOTE provides key information to make procedures easier or clearer.
NOTE:
•This manual should be considered apermanent part of this motorcycle and should remain with it
even if the motorcycle is subsequently sold.
•Yamaha continually seeks advancements in product design and quality. Therefore, while this
manual contains the most current product information available at the time of printing, there may
be minor discrepancies between your motorcycle and this manual. If there is any question con-
cerning this manual, please consult your Yamaha dealer.

IMPORTANT MANUAL INFORMATION
AWARNING
PLEASE READ THIS MANUAL AND THE "YOU AND YOUR MOTORCYCLE: RIDING TIPS"
BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE. DO
NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE ATTAINED ASATISFAC-
TORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE
BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND
CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU
SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.

AFFIX DEALER
LABEL HERE
XV535M/XV535MC
OWNER'S MANUAL
31999 by Yamaha Motor Corporation, U.S.A.
1st Edition, May 1999
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Corporation,
U.S.A. is expressly prohibited.
P/NLIT-1 1626-1 3-1
6

TABLE OF CONTENTS
1SAFETY INFORMATION
2DESCRIPTION
3INSTRUMENT AND CONTROL FUNCTIONS
4PRE-OPERATION CHECKS
5OPERATION AND IMPORTANT RIDING POINTS
6PERIODIC MAINTENANCE AND MINOR REPAIR
7CLEANING AND STORAGE
8SPECIFICATIONS
9CONSUMER INFORMATION
INDEX

dS SAFETY INFORMATION
Safety information 1-1
Safe riding 1-1
Protective apparel 1-2
Modification 1-3
Loading and accessories 1-3
Gasoline and exhaust gas 1-5
Location of the important labels 1-7

ASAFETY INFORMATION
TWO-WHEELED MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERA-
TION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EX-
PERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING
REQUIREMENTS BEFORE RIDING.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM ACOMPETENT SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER'S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER'S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1
.
Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and apassenger.
3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of au-
tomobile/motorcycle accidents. Many accidents have been caused by an automobile driver who did not
see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the chance
of this type of accident.
Therefore:
a. Wear abrightly colored jacket.
b. Use extra caution when you approach and pass through intersections, since intersections are the
most likely places for motorcycle accidents.
c. Ride where other motorists can see you. Avoid riding in another motorist's "blind spot".
1-1

£S SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have acurrent motorcycle license.
a. Make sure you are qualified. Also, only lend your motorcycle to experienced operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have be-
come thoroughly familiar with your motorcycle and all of its controls.
5. Many motorcycle accidents have been caused by motorcycle operator errors. Atypical error made by
the operator is veering wide on aturn due to EXCESSIVE SPEED or undercornering (insufficient lean
angle for the speed).
a. Always obey the speed limits and never travel faster than warranted by road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure other motorists see you.
6. The operator's and passenger's posture are important for proper control.
a. The operator should keep both hands on the handlebars and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold on to the operator, or the seat strap or grab bar if the motorcycle
is so equipped, with both hands and keep both feet on the passenger footrests.
c. Never carry apassenger unless he or she can firmly place both feet on the passenger footrests.
7. Never ride under the influence of alcohol or drugs.
8. This motorcycle is designed for on-road use only. It is not suitable for off-road use.
Protective apparel
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of asafety hel-
met is the single most critical factor in the prevention or reduction of head injuries.
1.Always wear an approved helmet.
1-2

ASAFETY INFORMATION
2. Wear aface shield or goggles. Wind on your unprotected eyes could contribute to an impairment of vi-
sion which could delay seeing ahazard.
3. The use of heavy boots, jacket, trousers, gloves, etc. is effective in preventing or reducing abrasions or
lacerations.
4. Never wear loose fitting clothing. It could catch on the control levers, footrests, or wheels and cause in-
jury or accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and can
cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
6. Apassenger should also observe the above precautions.
Modification
Modifications made to the motorcycle not approved by Yamaha, or the removal of original equipment, may
render your motorcycle unsafe for use and may cause severe personal injury. Modifications may also
make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight
distribution of the machine is changed. To avoid the possibility of an accident, extreme caution should be
used if adding cargo or accessories to your motorcycle. Use extra care if riding amotorcycle which has
added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding acces-
sories to your motorcycle:
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load
limit of XV535 :485 lb (220 kg) /XV535C :483 lb (219 kg).
1-3

ASAFETY INFORMATION
When loading within these weight limits, keep the following in mind:
1
.
Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Be sure to
distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or in-
stability.
2. Shifting weights can create asudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Recheck accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebars, front forks, or front fender. These items, in-
cluding such cargo as sleeping bags, duffle bags, or tents, can create unstable handling or slow steer-
ing response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha
cannot test all other accessories which may be available, you must personally be responsible for the prop-
er selection, installation and use of non-Yamaha accessories. You should use extreme caution when se-
lecting and installing any accessories.
Keep in mind these guidelines for mounting accessories in addition to those provided under "LOADING".
1.Never install accessories or carry cargo that would impair the performance of your motorcycle. Care-
fully inspect the accessory before using it to make sure it does not in any way reduce ground clearance
or cornering clearance, limit suspension travel, steering travel or control operation, or obscure lights or
reflectors.
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork
area, they must be as lightweight as possible and should be kept to aminimum.
1-4

/h SAFETY INFORMATION
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic
effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross
winds. These accessories may also cause instability when being passed by or passing large vehi-
cles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper
position limits the freedom of movement of the operator and may limit control ability. Therefore
such accessories are not recommended.
2. Caution must be used if adding electrical accessories. If these accessories exceed the capacity of the
motorcycle's electrical system, an electric failure could result, which could cause adangerous loss of
lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn off the engine when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in aclosed area. The exhaust fumes are poi-
sonous and may cause loss of consciousness and death within ashort time. Always operate your
motorcycle in an area that has adequate ventilation.
3. Always turn off the engine before leaving the motorcycle unattended and remove the ignition key.
When parking the motorcycle, note the following:
a. The engine and exhaust system may be hot. Park the motorcycle in aplace where pedestrians or
children are not likely to touch these hot areas.
b. Do not park the motorcycle on aslope or soft ground; the motorcycle may fall over.
c. Do not park the motorcycle near aflammable source, e.g. akerosene heater, or near an open
flame. The motorcycle could catch fire.
1-5

ASAFETY INFORMATION
4. When transporting the motorcycle in another vehicle, be sure it is kept upright and that the fuel cock is
turned to "ON" or "RES" (for vacuum type) /"OFF" (for manual type). If it should lean over, gasoline
may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale alot of gasoline vapor, or allow gasoline to get in your eyes,
see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it off with
soap and water and change your clothes.
1-6

ASAFETY INFORMATION
Location of the important labels
Please read the following labels carefully before operating this motorcycle.
1-7

ASAFETY INFORMATION
AWARNING
•BEFORE YOU OPERATE THIS VEHICLE, READ
THE OWNER'S MANUAL AND ALL LABELS.
•ALWAYS WEAR AN APPROVED MOTORCYCLE
HELMET, eye protection, and protective clothing.
3MX-2118K-A0
3California only
EMISSION HOSE ROUTING
CARB.
•S- FROM
QFUEL TANK
i
fr ^J
UCANISTER
TO ATMOSPHERE
4YN-21 686-00 J
CAUTION
Read owner's manual before servicing battery.
Electrolyte will damage metal parts or paint.
If electrolyte spills, wash area with fresh
water immediately.
Be sure to connect breather hose after
installing battery.
3JL-28177-A0
TIRE INFORMATION
Cold tire normal pressure should be set as
follows.
•Up to 90 kg (198 lbs) load
FRONT :200kPa, {2.00kgf/cm 2}, 29psi
REAR :225kPa, {2.25kgf/cm 2>, 33psi
•90 kg (198 lbs) ~maximum load
FRONT :200kPa, {2.00kgf/cm 2}, 29psi
REAR :250kPa, {2.50kgf/cm 2>, 36psi
1-8

DESCRIPTION
Left view 2-1
Right view 2-2
Controls/Instruments 2-3

DESCRIPTION
Left view
45
1
.
Headlight
2. Air filter
3. Rider seat
4. Tool kit
5. Passenger seat
(page 6-29)
(page 6-12)
(page 3-8)
(page 6-1)
(page 3-7)
6. Rear shock absorber spring
preload adjusting ring (page 3-9)
7. Main switch (page 3-1)
8. Starter (choke) "|\|" (page 3-6)
9. Shift pedal (page 3-4)
2-1

Right view
DESCRIPTION
10. Rear turn signal light
11
.
Sub fuel tank
12. Fuel tank
(page 6-30)
(page 3-5)
13. Front turn signal /position light (page 6-30)
14. Rear brake pedal (page 3-4)
15. Battery (page 6-26)
2-2