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Yamaha · Overhead-cam four-stroke twin, wet sump, gearbox shares engine oil, shaft drive

Virago XV535-XV1100

Library entry covers 1981-2007

35 factory 34 guideline

Published source

Yamaha Virago XV535 Owner's Manual, pp.6-3 to 6-5

Factory owner's handbook. Covers XV535 (owner's manual edition not dated in scan).

69 items for a 2003 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Electronic (CDI / transistor / ECU)
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Shaft
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Cast / alloy, tubeless
Sidecar: No sidecar

Maintenance schedule

2003 Yamaha Virago XV535-XV1100

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

Every 1,000 mi or 6 months

2 items

Adjust rear drum brake and rod / cable linkage

Brakes

Guideline
Inspect tire tread, sidewalls and date codes

Wheels and tires

Guideline

Every 3,000 mi or 12 months

6 items

Check throttle cable(s) free play and return

Fuel and air

Guideline
Clean fuel tap filter / sediment bowl

Fuel and air

Guideline
Check steering head bearing adjustment

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check brake pads and discs

Brakes

Guideline

Every 4,000 mi or 6 months

20 items

Change engine oil

Engine

Factory

Manual: Engine oil. Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi; also initial
Check and adjust valve clearances

Engine

Factory

Manual: Valve clearance. Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi; marked every column incl. initial
Crankcase ventilation system: Check ventilation hose for cracks or damage.

Engine

Factory

Factory: As printed: √ at 4,000 mi (7,000 km) or 6 months, 8,000 mi, 12,000 mi, 16,000 mi, 20,000 mi (31,000 km) or 30 months
Exhaust system: Check for leakage. Retighten if necessary.

Engine

Factory

Factory: As printed: √ at 4,000 mi (7,000 km) or 6 months, 8,000 mi, 12,000 mi, 16,000 mi, 20,000 mi (31,000 km) or 30 months
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Spark plugs (check, gap, clean). Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi
Clean / inspect air filter

Fuel and air

Factory

Manual: Air filter (clean with compressed air). Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi
Fuel line: Check fuel hose and vacuum pipe for cracks or damage.

Fuel and air

Factory

Factory: As printed: √ at 4,000 mi (7,000 km) or 6 months, 8,000 mi, 12,000 mi, 16,000 mi, 20,000 mi (31,000 km) or 30 months
Synchronize carburetors

Fuel and air

Factory

Manual: Carburetor synchronization. Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi; also initial
Check battery electrolyte, top up with distilled water

Ignition and electrics

Factory

Manual: Battery (check specific gravity, breather). Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Clutch (adjust free play). Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi; also initial
Brake pedal and shift pedal shaft: Lubricate. Apply chain lube lightly.

Final drive

Factory

Factory: As printed: √ at 4,000 mi (7,000 km) or 6 months, 8,000 mi, 12,000 mi, 16,000 mi, 20,000 mi (31,000 km) or 30 months
Brake/clutch lever pivot shaft: Apply chain lube lightly.

Final drive

Factory

Factory: As printed: √ at 4,000 mi (7,000 km) or 6 months, 8,000 mi, 12,000 mi, 16,000 mi, 20,000 mi (31,000 km) or 30 months
Sidestand pivot: Check operation and lubricate. Apply chain lube lightly.

Final drive

Factory

Factory: As printed: √ at 4,000 mi (7,000 km) or 6 months, 8,000 mi, 12,000 mi, 16,000 mi, 20,000 mi (31,000 km) or 30 months
Inspect fork seals, stanchions and fork boots

Front end

Factory

Manual: Front fork. Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi
Steering bearings: Check bearing assembly for looseness.

Front end

Factory

Factory: As printed: √ at 4,000, 8,000, 12,000 and 20,000 mi; Repack at 16,000 mi (25,000 km) or 24 months
Sidestand switch: Check and clean

Rear suspension and frame

Factory

Factory: As printed: √ at INITIAL 600 mi (1,000 km) or 1 month and every column to 20,000 mi (31,000 km) or 30 months
Brake system: Adjust free play.

Brakes

Factory

Factory: As printed: √ at INITIAL 600 mi (1,000 km) or 1 month and every column to 20,000 mi (31,000 km) or 30 months
Check wheel bearings for play

Wheels and tires

Factory

Manual: Wheel bearings. Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi
Idle speed: Check and adjust engine idle speed. Adjust cable free play.

Controls and cables

Factory

Factory: As printed: √ at 4,000 mi (7,000 km) or 6 months, 8,000 mi, 12,000 mi, 16,000 mi, 20,000 mi (31,000 km) or 30 months
Lubricate control cables and lever pivots

Controls and cables

Factory

Manual: Control and meter cable. Factory: Cols 600mi(1000km)/1mo initial, then 4000mi(7000km)/6mo spacing to 20000mi; also initial

Every 4,000 mi or 12 months

1 item

Lubricate brake cam spindles, check linings and drums

Brakes

Guideline

Every 6,000 mi or 12 months

6 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check final drive for leaks and bearing play

Final drive

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Guideline

A dry speedo cable whips the needle and eventually kills the instrument.

Every 8,000 mi or 12 months

3 items

Replace oil filter

Engine

Factory

Manual: Oil filter. Factory: Marked initial, 8000mi, 16000mi columns
Replace spark plugs

Engine

Factory

Manual: Spark plugs (replace). Factory: Replace at 8000mi(13000km)/12mo and thereafter every 8000mi
Evaporative emission control system** (California only): Check control system for damage.

Controls and cables

Factory

Factory: As printed: √ at 12,000 mi (19,000 km) or 18 months and 20,000 mi (31,000 km) or 30 months

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 2 years

2 items

Replace air filter element

Fuel and air

Guideline
Grease swingarm pivot

Rear suspension and frame

Guideline

Every 15,000 mi or 3 years

1 item

Change fork oil

Front end

Guideline

Some early telescopic forks are grease filled or use very small oil quantities. Check your manual.

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 16,000 mi or 2 years

4 items

Final gear oil: Check oil level and leakage.

Engine

Factory

Factory: As printed: Check at 8,000 mi (13,000 km) or 12 months (Replace at INITIAL, √ at 16,000 mi)
Change final drive (rear drive) oil

Final drive

Factory

Manual: Final gear oil. Factory: Replace at initial 600mi, then every 16000mi(25000km)/24mo; check 8000mi
Repack / replace steering head bearings

Front end

Factory

Manual: Steering bearings (repack). Factory: Moderately repack every 16000mi(25000km)
Replace swingarm bushes / bearings

Rear suspension and frame

Factory

Manual: Swingarm pivot bearing (repack). Factory: Moderately repack every 16000mi(25000km)

Every 20,000 mi or 4 years

2 items

Lubricate drive shaft splines / check U-joint

Final drive

Guideline
Repack / replace wheel bearings

Wheels and tires

Guideline

Cup-and-cone and taper roller hubs need periodic repacking and adjustment.

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 2 years

3 items

Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline
Replace brake fluid

Brakes

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

1 item

Replace tires on age (regardless of tread)

Wheels and tires

Guideline

No interval set

8 items

Crankcase ventilation system: Replace if necessary.

Engine

Factory

Factory: As printed: Replace if necessary.
Exhaust system: Replace gasket(s) if necessary.

Engine

Factory

Factory: As printed: Replace gasket(s) if necessary.
Air filter: Replace if necessary.

Fuel and air

Factory

Factory: As printed: Replace if necessary.
Fuel line: Replace if necessary.

Fuel and air

Factory

Factory: As printed: Replace if necessary.
Sidestand switch: replace if necessary.

Rear suspension and frame

Factory

Factory: As printed: Check and clean or replace if necessary.
Brake system: Replace pads if necessary. (Front)

Brakes

Factory

Factory: As printed: Replace pads if necessary. (Front)
Brake system: Replace shoes if necessary. (Rear)

Brakes

Factory

Factory: As printed: Replace shoes if necessary. (Rear)
Evaporative emission control system**: Replace if necessary.

Controls and cables

Factory

Factory: As printed: Replace if necessary.

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.