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Chapter 1 Tune-up and routine maintenance
Specifications
XV535
Engine
Spark plugs
Type NGK BP7ES or ND W22EP-U
Gap 0.7 to 0.8 mm (0.028 to 0.032 inch)
Valve clearances (COLD engine)
Intake 0.07 to 0.12 mm (0.003 to 0.005 inch)
Exhaust 0.12 to 0.17 mm (0.005 to 0.007 inch)
Engine idle speed 1150 to 1250 rpm
Cylinder compression pressure (at sea level)
Standard 10.75 Bars (156 psi)
Maximum... 11.78 Bars (171 psi)
Minimum 9.78 Bars (142 psi)
Maximum difference between cylinders 0.96 Bars (14 psi)
Carburetor synchronization
Vacuum at idle speed 230 mm Hg (9.06 inch Hg)
Maximum vacuum difference between cylinders 10 mm Hg (0.39 inch Hg)
Cylinder numbering (from rear to front of bike)... 1-2
Miscellaneous
Brake pedal position.. . 38 mm (1.5 inch) above the top of the footpeg
Shift pedal position 50 to 60 mm (2.0 to 2.4 inches) above the top of the footpeg
Freeplay adjustments
Throttle grip 2 to 5 mm (0.08 to 0.20 inch)
Clutch lever 2 to 3 mm (0.08 to 0.12 inch)
Front brake lever 2 to 5 mm (0.08 to 0.20 inch)
Rear brake pedal .... 20 to 30 mm (0.8 to 1.2 inches)
Battery electrolyte specific gravity 1.280 at 20-degrees C (68-degrees F)
Minimum tire tread depth* 1 mm (0.04 inch)
Tire pressures (cold)
Front
1987 and 1988 US, all UK models... 1.93 Bars (28 psi)
1989 and later US models 1.99 Bars (29 psi)
Rear
Up to 90 kg (198 lbs)
1987 and 1988 US, all UK models 2.2 Bars (32 psi)
1989 and later US models . 2.27 Bars (33 psi)
Above 90 kg (198 lbs) or high speed riding 2.48 bars (36 psi)
Torque specifications
Oil drain plug 43 Nm (31 ft-lbs)
Oil filter cover bolts 10 Nm (7.2 ft-lbs)
Spark plugs 12.5 Nm (9 ft-lbs)
Steering head bearing ring nuts
Initial torque 38 Nm (27 ft-lbs)
Final torque 10 Nm (7.2 ft-lbs)
Steering stem bolt 54 Nm (39 ft-lbs)
Valve adjuster locknuts . 14 Nm (10 ft-lbs)
Rocker cover bolts 10 Nm (7.2 ft-lbs)
Final drive filler and drain plugs 23 Nm (17 ft-lbs)
Recommended lubricants and fluids
Fuel type
US . Unleaded
UK Regular
Fuel capacity
1987 and 1988 models
Total......... 8.6 liters (2.3 US gal, 1.9 Imp gal)
Reserve 2.0 liters (0.5 US gal, 0.4 Imp gal)
1989 and later models
Total . 13.5 liters (3.6 US gal, 3.0 Imp gal)
Reserve.. 2.5 liters (0.7 US gal, 0.5 Imp gal)
Engine/transmission oil
Type API grade SE or SF
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