How to Remove a Virago 535 Carburetor

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The Virago XV 535 was a middleweight V-twin-engined cruiser-style motorcycle produced by Yamaha from 1987 to 2003. The Virago 535 used a dual carburetor system to feed both of the engine's cylinders. Periodic cleaning of the carburetors' float chambers, fuel jets and internal diaphragms is required to prevent gasoline from reducing to a thick slime over time. Removing and installing the carburetors from the Virago is complicated by the location of the gas tank below the rider's seat, as well as the secondary or false gas tank mounted in the traditional position above the engine.

Things You'll Need

  • Socket wrench
  • Socket set
  • Phillips screwdriver
  • Pliers
  • Small pry bar
  • Torque wrench

Carburetor Removal

  • Place the motorcycle on a service stand to hold it in an upright position. Let the engine cool for a minimum of one hour.

  • Unlock the seat latch, using the ignition key, then lift the seat off the motorcycle's frame. Pull the plastic covers off both sides of the frame. Remove the electrical panel, located under the left seat rail, using a socket wrench.

  • Unscrew the bolt at the base of the gas tank, then both mounting bolts near the steering pivot, using a socket wrench. Lift the gas tank off the motorcycle and pull the fuel hoses off both sides of the gas tank. If you are working on a 1987 to 1989 XV 535, remove the false gas tank as described above. There are no fuel hoses attached the false gas tank.

  • Remove the clips securing the wiring harness to the frame, directly above the carburetors on the right side of the motorcycle, using a Phillips screwdriver. Pull the fuel hose off the carburetor fuel inlet on the left side of the motorcycle using pliers.

  • Loosen the air box duct clamps, located at the top of the carburetors, and the engine intake clamps on the bottom of the carburetors using a Phillips screwdriver. Push the air box ducts off the carburetors using a small pry bar. Pull the carburetors up and out of the engine intakes. Remove the carburetors from the left side of the engine.

  • Pull the throttle cable up and out of the cable holder at the center of the carburetors. Pull the inner steel cable through the slot cut into the cable holder, then pull the cable end out of the carburetor throttle pulley.

Carburetor Installation

  • Hold the carburetors against the left side of the engine. Push the throttle cable end into the throttle pulley, then slip the inner cable through the cable holder slot. Push the throttle cable into the cable holder.

  • Push the carburetors into the engine intakes, then tighten the intake clamps using a Phillips screwdriver. Push the air box ducts over the carburetor inlets, then tighten the air box duct clamps.

  • Push the fuel hose onto the carburetor fuel inlet. Mount the gas tank onto the motorcycle's frame. Screw the gas tank mounting bolts into place at the base of the tank and near the steering head, using a socket wrench. Tighten the bolts to 14 foot-pounds using a torque wrench. Reconnect the fuel hoses to the outlets on the bottom of the tank if you are working on a 1990 or newer XV 535 model.

  • Bolt the electrical panel to the left frame rail, then tighten the panel bolt to 7.8 foot-pounds. Push both side panels onto the grommets mounted on both sides of the motorcycle's frame rails. Reinstall the seat, then push down on the front of the seat cushion until the seat latch locks into place.

  • Lower the motorcycle from its center stand and park it on its side stand.

Tips & Warnings

  • Flammable gasoline vapors will be released while you are working with your XV 535's fuel system. These vapors can ignite if exposed to an open flame or sparks. Do not smoke or work near an open flame while removing or installing the motorcycle's carburetors.
  • Prolonged contact with gasoline may cause some skin irritation. Wear protective gloves while servicing your motorcycle's fuel system to minimize direct skin contact with gasoline.

References

  • 1988 Yamaha XV535U Service Manual; Yamaha Motor Corporation
  • 1993 Yamaha XV535E Service Manual; Yamaha Motor Corporation
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