User Guide

Chapter 3 Part A Fuel and exhaust systems (XV535 models)
3A-3
2.4a Release the fuel hoses from the clips on top of the
battery cover
A Clips
B Hose clamps
C Tank mounting bolts
D Battery positive cable
(always disconnect the
negative cable first)
2.4b Fuel tanks and lines (models with upper fuel tank)
1 Fuel lines
2 Fuel filter
3 Fuel pump
4 Fuel tap
5 Lower fuel tank
6 Upper fuel tank
2.5a Remove the upper tank mounting bolt at the rear ...
2.5b ... and one on each side
1 General information
The fuel system consists of the fuel tank, the fuel tap and filter,
the carburetors and the connecting lines, hoses and control cables and
an electric fuel pump.
The carburetors used on these motorcycles are two Mikunis with
butterfly-type throttle valves. For cold starting, an enrichment circuit is
actuated by a choke lever mounted on the left side of the bike.
The exhaust system routes exhaust gases into a muffler/silencer
chamber under the bike and then into twin exhaust pipes on the right
side.
Many of the fuel system service procedures are considered routine
maintenance items and for that reason are included in Chapter 1.
2 Fuel tank - removal and installation
Warning: Gasoline (petrol) is extremely flammable, so take extra
precautions when you work on any part of the fuel system. Don't smoke
or allow open flames or bare light bulbs near the work area, and don't
work in a garage where a natural gas-type appliance (such as a water
heater or clothes dryer) is present. If you spill any fuel on your skin,
rinse it off immediately with soap and water. When you perform any
kind of work on the fuel system, wear safety glasses and have a fire
extinguisher suitable for class B fires (flammable liquids) on hand.
1 All models have a main fuel tank mounted beneath the seat. Later
models also have an upper fuel tank mounted forward of the seat on
top of the upper frame section in the traditional position (on early
models, what looks like a fuel tank is actually a cover).
2 Support the bike securely so it can't be knocked over during this
procedure.
3 Remove the seat (see Chapter 7).
Upper fuel tank
Refer to illustrations 2.4a, 2.4b, 2.5a, 2.5b, 2.6a and 2.6b
4 Free the fuel hoses from the clips on top of the battery cover,
remove the cover and disconnect the negative cable from the battery
(see illustrations).
5 Remove the upper tank mounting bolts and washers (see
illustrations). Remove the metal collars from inside the left and right
rubber dampers, then remove all three dampers.