Yamaha XV19SX(C) Service Manual

Table of Contents

Quick Links

Download this manual

2008

SERVICE MANUAL

XV19SX(C)

XV19MX(C)

XV19CTSX(C)

XV19CTMX(C)

XV19CSX(C)

XV19CX(C)

LIT-11616-21-26

1D7-28197-12

Table of Contents

Chapters

Table of Contents

Troubleshooting

Summary of Contents for Yamaha XV19SX(C)

Page 1 2008 SERVICE MANUAL XV19SX(C) XV19MX(C) XV19CTSX(C) XV19CTMX(C) XV19CSX(C) XV19CX(C) LIT-11616-21-26 1D7-28197-12...
Page 2 EAS20050 XV19SX(C)/XV19MX(C)/XV19CTSX(C)/ XV19CTMX(C)/XV19CSX(C)/XV19CX(C) SERVICE MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. First edition, June 2007 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-21-26...
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4: How To Use This Manual
EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5: Symbols
EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) ................... 1-4 INSTRUMENT FUNCTIONS (for XV19CS(C)/ XV19C(C)) .......1-7 IMPORTANT INFORMATION ............... 1-11 PREPARATION FOR REMOVAL AND DISASSEMBLY......
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES ET1D71017 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES ET1D71018 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Instrument Functions (For Xv19S(C)/ Xv19M(C)/ Xv19Cts(C)/ Xv19Ctm(C))
FEATURES ET1D71036 INSTRUMENT FUNCTIONS (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) Multi-function meter unit EW1D71008 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. “SELECT” switch 1. Speedometer 2. “RESET” switch 2. Fuel gauge 3.
Page 14 FEATURES Tachometer • The fuel gauge does not indicate the correct fuel level for the first 5 km/h (3 mi/h) after refu- eling. Odometer, tripmeter, and clock modes 1. Tachometer 2. Tachometer red zone The electric tachometer allows the rider to mon- itor the engine speed and keep it within the ideal 1.
Page 15 FEATURES To set the clock: Select the brightness control mode as follows. 1. Push the “SELECT” switch to change the dis- 1. Turn the key to “OFF”. play to the clock mode. 2. Push and hold the “SELECT” switch. 2. Push the “SELECT” and “RESET” switches 3.
Page 16: Instrument Functions (For Xv19Cs(C)/ Xv19C(C))
FEATURES • a fuel reserve tripmeter (which shows the dis- tance traveled on the fuel reserve) • a clock • a self-diagnosis device • a brightness control mode NOTE: Be sure to turn the key to “ON” before using the “SELECT”...
Page 17 FEATURES Fuel gauge b. Estimation range c. Main fuel tank estimation range d. Sub-fuel tank estimation range e. Fuel level warning light activation point f. Main fuel tank g. Sub-fuel tank These models are equipped with two fuel tanks: the main fuel tank and the sub-fuel tank. Since the fuel sender, which is used to detect the fuel level, is installed in the main fuel tank, it is not able to detect the fuel level throughout the entire...
Page 18 If the odometer/tripmeter/clock display indicates order: any error codes, note the code number, and ODO → TRIP A → TRIP B → ODO then have a Yamaha dealer check the vehicle. If the fuel level warning light comes on, the ECA1D77001 CAUTION: odometer display will automatically change to the fuel reserve tripmeter mode “F-TRIP”...
Page 19 FEATURES To set the brightness 1. Turn the key to “OFF”. 2. Push and hold the “SELECT” switch. 3. Turn the key to “ON”, and then release the “SELECT” switch after five seconds. 1. Multi-function meter unit panel 2. Brightness level 4.
Page 20: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 21: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropri- ate.
Page 22: Checking The Connections
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...
Page 23: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Timing light 3-10 90890-03141 Inductive clamp timing light YU-03141 Oil filter wrench 3-12 90890-01426 YU-38411 Belt tension gauge 3-26 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-27, 4-81 90890-01403 Spanner wrench YU-33975 Damper rod holder...
Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide remover (ø6) 5-43 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6) 5-43 90890-04065 Valve guide installer (6.0 mm) YM-04065-A Valve guide reamer (ø6) 5-43 90890-04066 Valve guide reamer (6.0 mm) YM-04066 Piston pin puller set 5-49...
Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Yamaha bond No. 1215 5-70, 5-80, 90890-85505 5-98 (Three Bond No.1215®) Rotor puller 5-79 90890-01080 Stator rotor puller YM-01080-A Vacuum/pressure pump gauge set 6-16 90890-06756 Mityvac brake bleeding tool YS-42423 Pressure gauge...
Page 27: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-3 CHASSIS SPECIFICATIONS ................2-11 ELECTRICAL SPECIFICATIONS ..............2-16 TIGHTENING TORQUES ................2-20 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-20 ENGINE TIGHTENING TORQUES............2-21 CHASSIS TIGHTENING TORQUES............2-26 LUBRICATION POINTS AND LUBRICANT TYPES ........2-33 ENGINE....................2-33 CHASSIS....................2-35 LUBRICATION SYSTEM CHART AND DIAGRAMS........
Page 28: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XV19SX 1D77 (USA) XV19SXC 1D78 (California) XV19SX 1D79 (CDN) XV19MX 4D57 (USA) XV19MXC 4D58 (California) XV19MX 4D59 (CDN) XV19CTSX 2C57 (USA) XV19CTSXC 2C58 (California) XV19CTSX 2C59 (CDN) XV19CTMX 4P17 (USA) XV19CTMXC 4P18 (California) XV19CTMX 4P19 (CDN) XV19CSX 29P1/5C71 (USA) XV19CSXC 29P2/5C72 (California)
Page 29 GENERAL SPECIFICATIONS Ground clearance XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 155 mm (6.10 in) XV19CS(C)/ XV19C(C): 146 mm (5.75 in) Minimum turning radius XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 3480 mm (137.0 in) XV19CS(C)/ XV19C(C): 3500 mm (137.8 in) Weight With oil and fuel XV19S(C)/ XV19M(C): 340.0 kg (750 lb) XV19CTS(C)/ XV19CTM(C):...
Page 30: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, OHV Displacement 1854.0 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 100.0 × 118.0 mm (3.94 × 4.65 in) Compression ratio 9.48 :1 Starting system Electric starter Fuel Recommended fuel Premium unleaded gasoline only Fuel tank capacity XV19S(C)/ XV19M(C)/ XV19CTS(C)/...
Page 31 ENGINE SPECIFICATIONS Oil-pump-housing-to-inner-and-outer-rotor clearance 0.06–0.13 mm (0.0024–0.0051 in) Limit 0.20 mm (0.0079 in) Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 kgf/cm²) Relief valve operating pressure 600.0 kPa (87.0 psi) (6.00 kgf/cm²) Transfer gear oil pump Oil pump type Trochoid Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Page 32 ENGINE SPECIFICATIONS Limit 35.850 mm (1.4114 in) Rocker arm/rocker arm shaft Rocker arm inside diameter 18.000–18.018 mm (0.7087–0.7094 in) Limit 18.036 mm (0.7101 in) Rocker arm shaft outside diameter 17.976–17.991 mm (0.7077–0.7083 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in) Limit 0.080 mm (0.0032 in) Valve, valve seat, valve guide Valve clearance (cold)
Page 33 ENGINE SPECIFICATIONS Limit 6.050 mm (0.2382 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Valve spring Free length (intake) 46.71 mm (1.84 in) Limit...
Page 34 ENGINE SPECIFICATIONS Cylinder Bore 100.000–100.010 mm (3.9370–3.9374 in) Taper limit 0.050 mm (0.0020 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in) Limit 0.15 mm (0.0059 in) Diameter D 99.960–99.975 mm (3.9354–3.9360 in) Height H 10.0 mm (0.39 in) Offset...
Page 35 ENGINE SPECIFICATIONS Oil ring Dimensions (B × T) 2.50 × 3.40 mm (0.10 × 0.13 in) End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) Connecting rod Oil clearance (using plastigauge®) 0.050–0.074 mm (0.0020–0.0029 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow Crankshaft Width A 105.80–106.20 mm (4.165–4.181 in)
Page 36 ENGINE SPECIFICATIONS Secondary reduction system Belt drive Secondary reduction ratio XV19SX(C)/ XV19MX(C)/ XV19CTSX(C)/ XV19CTMX(C): 70/31 (2.258) XV19CS(C)/ XV19C(C): 66/31 (2.129) Operation Left foot operation Gear ratio 38/16 (2.375) 33/21 (1.571) 29/25 (1.160) 26/28 (0.929) 24/30 (0.800) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in)
Page 37 ENGINE SPECIFICATIONS Throttle position sensor Resistance XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 4.0–6.0 kΩ/blue-black XV19CS(C)/ XV19C(C): 3.1–5.7 kΩ/blue-black Output voltage (at idle) 0.63–0.73 V Fuel injection sensor 248–372 Ω Crankshaft position sensor resistance Intake air pressure sensor output voltage 3.75–4.25 V Engine temperature sensor resistance 0.90–1.10 kΩ...
Page 38: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 31.30 ° XV19CS(C)/ XV19C(C): 33.20 ° Trail XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 152.0 mm (5.98 in) XV19CS(C)/ XV19C(C): 102.0 mm (4.02 in) Front wheel Wheel type Cast wheel Rim size XV19S(C)/ XV19M(C)/ XV19CTS(C)/...
Page 39 CHASSIS SPECIFICATIONS Manufacturer/model XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): DUNLOP/D251F Manufacturer/model XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): BRIDGESTONE/G851 RADIAL G Manufacturer/model XV19CS(C)/ XV19C(C): METZELER/880 MARATHON Wear limit (front) 1.0 mm (0.04 in) Rear tire Type Tubeless Size XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 190/60R17M/C 78H XV19CS(C)/ XV19C(C): 210/40R18M/C 73H Manufacturer/model XV19S(C)/ XV19M(C)/ XV19CTS(C)/...
Page 40 CHASSIS SPECIFICATIONS Limit 0.5 mm (0.02 in) Master cylinder inside diameter 14.00 mm (0.55 in) Caliper cylinder inside diameter 27.00 mm (1.06 in) Caliper cylinder inside diameter 30.23 mm (1.19 in) Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Brake pedal position...
Page 41 Inner tube outer diameter 46.0 mm (1.81 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 571.0 cm³ (19.31 US oz) (20.10 Imp.oz) XV19CS(C)/ XV19C(C): 755.0 cm³ (25.53 US oz) (26.58 Imp.oz)
Page 42 CHASSIS SPECIFICATIONS Limit XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 176.4 mm (6.94 in) XV19CS(C)/ XV19C(C): 183.3 mm (7.22 in) Installed length XV19S(C)/ XV19M(C): 171.0 mm (6.73 in) XV19CTS(C)/ XV19CTM(C): 165.0 mm (6.50 in) XV19CS(C)/ XV19C(C): 172 mm (6.77 in) Spring rate K1 XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 176.50 N/mm (1007.82 lb/in) (18.00 kgf/mm)
Page 43: Electrical Specifications
10.0 °/900 r/min Engine control unit Model/manufacturer XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): F008T83271/MITSUBISHI XV19CS(C)/ XV19C(C): F008T83971/MITSUBISHI Ignition coil Model/manufacturer 2JN/YAMAHA Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ Spark plug cap Material Resin Resistance 10.0 kΩ...
Page 44 High beam indicator light Fuel level warning light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer 1D7/YAMAHA Power output 0.90 kW 0.0081–0.0099 Ω Armature coil resistance Brush overall length 9.8 mm (0.39 in) Limit 5.00 mm (0.20 in)
Page 45 Turn signal blinking frequency 75.0–95.0 cycles/min 21(23) W × 2 + LED × 2 Wattage Fuel gauge Model/manufacturer XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C) 1D7/YAMAHA XV19CS(C)/ XV19C(C): 5C7/NIPPON SEIKI 9–11 Ω Sender unit resistance (full) 213–219 Ω Sender unit resistance (empty) Starting circuit cut-off relay...
Page 46 ELECTRICAL SPECIFICATIONS Spare fuse 3.0 A 2-19...
Page 47: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 48: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head nut 60 Nm (6.0 m·kg, 43 ft·lb) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe) Spark plug 18 Nm (1.8 m·kg, 13 ft·lb) Engine temperature sensor —...
Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pipe 4 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pump housing cover 1 screw 7 Nm (0.7 m·kg, 5.1 ft·lb) (crankcase) Oil pump housing cover 2 screw 7 Nm (0.7 m·kg, 5.1 ft·lb) (crankcase) Throttle body joint clamp screw 3 Nm (0.3 m·kg, 2.2 ft·lb)
Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Crankshaft position sensor lead 10 Nm (1.0 m·kg, 7.2 ft·lb) holder screw Clutch cover damper plate screw 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Generator cover damper bolt 5 Nm (0.5 m·kg, 3.6 ft·lb) Engine oil filler plug...
Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Transfer gear case oil pump as- 10 Nm (1.0 m·kg, 7.2 ft·lb) sembly bolt Oil pump housing screw (transfer 4 Nm (0.4 m·kg, 2.9 ft·lb) gear case) Transfer gear oil check bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Transfer gear case bolt 50 Nm (5.0 m·kg, 36 ft·lb)
Page 52 TIGHTENING TORQUES Cylinder head tightening sequence: A. Front cylinder B. Rear cylinder 2-25...
Page 53: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (left upper 66 Nm (6.6 m·kg, 48 ft·lb) side) Engine mounting bolt (right upper 59 Nm (5.9 m·kg, 43 ft·lb) side)*1, 2 Engine mounting bolt (right upper 66 Nm (6.6 m·kg, 48 ft·lb) side)*3 Engine mounting nut (rear upper...
Page 54 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Horn 2 bolt*3 10 Nm (1.0 m·kg, 7.2 ft·lb) ISC (idle speed control) unit bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) ISC (idle speed control) unit 7 Nm (0.7 m·kg, 5.1 ft·lb) bracket bolt Pivot shaft nut 125 Nm (12.5 m·kg, 90 ft·lb)
Page 55 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower ring nut (final tightening 18 Nm (1.8 m·kg, 13 ft·lb) torque) NOTE. Hose guide and lower handlebar 32 Nm (3.2 m·kg, 23 ft·lb) holder nut*1, 2 Hose guide and lower handlebar 40 Nm (4.0 m·kg, 29 ft·lb) holder nut*3 Front brake master cylinder hold-...
Page 56 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Fuel tank and fuel tank bracket 7 Nm (0.7 m·kg, 5.1 ft·lb) bolt (front side) Fuel tank and fuel tank bracket 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt (rear side) Meter cover bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel pump bolt 5 Nm (0.5 m·kg, 3.6 ft·lb)
Page 57 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Positive battery lead bolt (starter 7 Nm (0.7 m·kg, 5.1 ft·lb) relay side)*1, 2 Starter motor lead bolt (starter 5 Nm (0.5 m·kg, 3.6 ft·lb) relay side)*3 Positive battery lead bolt (starter 5 Nm (0.5 m·kg, 3.6 ft·lb) relay side)*3 Rear fender bracket and frame...
Page 58 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Locknut (shift rod) 12 Nm (1.2 m·kg, 8.7 ft·lb) Shift arm bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Shift pedal bolt (toe side)*1, 2 14 Nm (1.4 m·kg, 10 ft·lb) Shift pedal bolt (heel side)*1, 2 13 Nm (1.3 m·kg, 9.4 ft·lb) Shift pedal bolt*3 30 Nm (3.0 m·kg, 22 ft·lb)
Page 59 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Sidebag bracket bolt*2 23 Nm (2.3 m·kg, 17 ft·lb) Sidebag bracket brace nut*2 23 Nm (2.3 m·kg, 17 ft·lb) *1 For XV19S(C)/ XV19M(C) *2 For XV19CTS(C)/ XV19CTM(C) *3 For XV19CS(C)/ XV19C(C) NOTE: 1.
Page 60: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nuts and washers Connecting rod small end and big end Crankshaft journals Piston surfaces Piston pins Connecting rod bolts Balancer idle gear inner surface and balancer idle gear shaft Left balancer driven gear inner surface Right balancer...
Page 61 Middle drive gear nut and conical spring washer Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal Shift fork pawl Yamaha bond Crankcase mating surface No.1215 (Three Bond No.1215®) Yamaha bond Stator coil lead grommet No.1215 (Three Bond...
Page 62: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing dust cover lip Lower bearing dust seal lip Lower bracket steering shaft*1 Steering stem bolt*1 Front wheel oil seal lips (left and right) Rear wheel oil seal lips Rear wheel drive hub oil seal lip Rear wheel drive hub mating surface Tube guide (throttle grip) inner surface and throttle cables...
Page 63 LUBRICATION POINTS AND LUBRICANT TYPES 2-36...
Page 64: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-37...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer (transfer gear case) 2. Oil pump 3. Oil tank 4. Drive axle 5. Main axle 6. Oil strainer (crankcase) 7. Balancer 8. Front cylinder head cover 9. Rear cylinder head cover 10. Rear cylinder camshaft 11.
Page 66: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-39...
Page 67 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil tank 2. Dipstick 3. Oil pipe 2 4. Oil delivery pipe 1 5. Oil filter cartridge 6. Oil delivery pipe 2 7. Oil pipe 3 8. Oil pipe 4 9. Oil pipe 5 10.
Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Valve lifter 2. Push rod 3. Rocker arm shaft 4. Oil pipe 1 5. Crankshaft 6. Oil pipe (“F” mark) 7. Oil pipe (“R” mark) 2-42...
Page 70 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-43...
Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 1 2. Oil pump 3. Oil strainer (crankcase) 4. Joint pipe 2-44...
Page 72 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-45...
Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil strainer (crankcase) 4. Oil pump A. To the oil filter cartridge 2-46...
Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-47...
Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 5 2. Transfer gear oil pump 3. Oil strainer (transfer gear case) 4. Middle drive shaft 5. Oil strainer (oil tank) A. From the oil pump 2-48...
Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-49...
Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Transfer gear oil pump 2. Middle driven shaft 2-50...
Page 78: Cable Routing (For Xv19S(C)/ Xv19M(C)/ Xv19Cts(C)/ Xv19Ctm(C))
CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) EAS20430 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 2-51...
Page 79 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Clutch hose 2. Right handlebar switch lead 3. Main switch 4. Left handlebar switch lead 5. Front brake hose 6. Throttle cable (decelerator cable) 7. Throttle cable (accelerator cable) 8. Horn 1 lead 9.
Page 80 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 2-53...
Page 81 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Main switch lead 2. Right handlebar switch lead 3. Wire harness 4. Left handlebar switch lead 5. Air temperature sensor lead 6. Front left turn signal/position light lead 7. Headlight lead 8. Front right turn signal/position light lead 9.
Page 82 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 2-55...
Page 83 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. EXUP servo motor J. Fasten the wire harness and the cylinder-#2 left and right spark plug leads with a plastic locking tie, 2. Fuse box making sure to install the tie just past the end of the 3.
Page 84 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 2 3 4 15 16 2-57...
Page 85 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Clutch hose K. Fasten the stator coil lead and rectifier/regulator lead with the plastic locking tie. Face the end of the 2. Throttle cable (decelerator cable) plastic locking tie outward, and then cut off the 3.
Page 86 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 16 17 2-59...
Page 87 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Meter assembly coupler L. Fasten the air filter case damper with the plastic locking tie so that the rubber part of the damper 2. Cylinder-#2 intake air pressure sensor coupler contacts the frame. Be sure to pass the plastic 3.
Page 88 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 2-61...
Page 89 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Fuel tank breather hose Q. Install the fuel hose (fuel tank to fuel hose joint) with its white paint mark facing downward. 2. Fuel sender (fuel tank) R. To the pressure regulator 3.
Page 90 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 2-63...
Page 91 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#1 intake air pressure sensor hose 3. Air filter case breather hose 1 4. Fuel hose (intake manifold assembly to pressure regulator) 5. Pressure regulator 6. Air filter case breather hose 2 7.
Page 92 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 9 10 2-65...
Page 93 CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor hose 3. Cylinder-#2 intake air pressure sensor 4. ISC (idle speed control) unit coupler 5. ISC (idle speed control) unit 6. Rollover valve 1 7.
Page 94: Cable Routing (For Xv19Cs(C)/ Xv19C(C))
CABLE ROUTING (for XV19CS(C)/ XV19C(C)) EAS1D77001 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-67...
Page 95 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. Clutch hose 2. Left handlebar switch lead 3. Right handlebar switch lead 4. Front brake hose 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Horn 1 lead 8. Horn 9. Rear brake light switch lead 10.
Page 96 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-69...
Page 97 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. Front right turn signal/position light lead 2. Wire harness 3. Main switch lead 4. Accessory light coupler 5. Joint coupler 6. Air temperature sensor lead 7. Front left turn signal/position light lead 8. Right handlebar switch lead 9.
Page 98 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) E F F 2-71...
Page 99 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. EXUP servo motor P. To the neutral switch 2. Fuse box Q. To the speed sensor 3. Wire harness R. Pass the O sensor lead through the cutout in the heat protector. 4. Fuel outlet hose S.
Page 100 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-73...
Page 101 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. Clutch hose J. Fasten the starter motor lead, horn 1 lead, rear brake light switch lead, sidestand switch lead, 2. Throttle cable (accelerator cable) crankshaft position sensor lead and 3. Throttle cable (decelerator cable) rectifier/regulator lead to the frame with a plastic 4.
Page 102 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-75...
Page 103 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. Cylinder-#2 intake air pressure sensor coupler O. Route the positive battery lead (battery to starter relay) under the tray. 2. Meter assembly coupler P. View with tray installed 3. Fuel sender (fuel tank) coupler Q.
Page 104 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-77...
Page 105 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. Fuel tank breather hose 2. Fuel tank 3. Air vent hose (fuel hose joint to fuel tank) 4. Fuel hose (fuel tank to fuel hose joint) 5. Fuel return hose (fuel return pipe to sub-fuel tank) 6.
Page 106 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-79...
Page 107 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#1 intake air pressure sensor hose 3. Air filter case breather hose 1 4. Fuel hose (intake manifold assembly to pressure regulator) 5. Pressure regulator 6. Canister purge hose (for California only) 7.
Page 108 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-81...
Page 109 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor hose 3. Cylinder-#2 intake air pressure sensor 4. ISC (idle speed control) unit coupler 5. ISC (idle speed control) unit 6. ISC (idle speed control) unit inlet hose 7.
Page 110 CABLE ROUTING (for XV19CS(C)/ XV19C(C)) 2-83...
Page 111: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES.......... 3-7 ADJUSTING THE THROTTLE CABLE FREE PLAY ........3-8 CHECKING THE SPARK PLUGS .............
Page 112 CHASSIS ....................... 3-21 ADJUSTING THE REAR DISC BRAKE ..........3-21 CHECKING THE BRAKE FLUID LEVEL..........3-21 CHECKING THE FRONT BRAKE PADS ..........3-22 CHECKING THE REAR BRAKE PADS ..........3-22 CHECKING THE FRONT BRAKE HOSES ..........3-23 CHECKING THE REAR BRAKE HOSES..........3-23 ADJUSTING THE REAR BRAKE LIGHT SWITCH .........3-23 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........
Page 114: Periodic Maintenance
√ √ damage. tem (for California • Replace if necessary. only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32185 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 8000 mi...
Page 115 25 * Front and rear √ √ √ √ √ √ • Check operation. brake switches • Apply Yamaha chain and ca- √ √ √ √ √ √ 26 * Control cables ble lube or engine oil SAE 10W-30 thoroughly.
Page 116 PERIODIC MAINTENANCE * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 117: Engine
ENGINE • Fuel tank EAS20470 ENGINE Refer to “FUEL TANK” on page 6-1. • Air filter case EAS20530 Refer to “GENERAL CHASSIS” on page 4-1. ADJUSTING THE VALVE CLEARANCE • Muffler The following procedure applies to all of the • Exhaust pipes valves.
Page 118 ENGINE 8. Remove: 11.Measure: • Fuel tank damper “1” • Valve clearance • Cylinder head breather hose “2” Out of specification → Adjust. 9. Disconnect: • Oil tank breather hose “3” Valve clearance (cold) Intake • Fuel outlet hose “4” 0.00–0.04 mm (0.0000–0.0016 in) Exhaust 0.00–0.04 mm (0.0000–0.0016 in)
Page 119 ENGINE Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 L LLL L LLL L LLL L LLL L LLL 12.Adjust: • Valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut “1”. d. Measure the valve clearance with a thickness gauge.
Page 120: Synchronizing The Throttle Bodies
ENGINE • Fuel tank Refer to “FUEL TANK” on page 6-1. 3. Remove: • Cylinder-#1 intake air pressure sensor brack- et “1” • Cylinder-#2 intake air pressure sensor brack- et “2” d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion.
Page 121: Adjusting The Throttle Cable Free Play
ENGINE NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg). L LLL L LLL L LLL L LLL L LLL 8. Stop the engine and remove the measuring equipment. 9. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- 6.
Page 122: Checking The Spark Plugs
ENGINE b. Turn the adjusting nut “2” in direction “a” or “b” Manufacturer/model until the specified throttle cable free play is NGK/DPR8EA-9 obtained. Manufacturer/model DENSO/X24EPR-U9 Direction “a” Throttle cable free play is increased. 5. Check: Direction “b” • Electrode “1” Throttle cable free play is decreased.
Page 123: Checking The Ignition Timing
ENGINE EAS20700 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Stand the vehicle on a level surface. 2.
Page 124: Checking The Engine Oil Level
ENGINE NOTE: Type Align the mark “a” on the shift pedal shaft with YAMALUBE 4 (20W40) or the slot in the shift pedal. SAE20W40 Recommended engine oil grade API service SG type or higher, JASO standard MA ECA13380 CAUTION: • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage.
Page 125 ENGINE c. Tighten the new oil filter cartridge to specifi- 5. Remove: cation with an oil filter wrench. • Engine oil drain bolts (crankcase) “1” (along with the gaskets) Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) L LLL L LLL L LLL L LLL...
Page 126: Checking The Transfer Gear Oil Level
ENGINE EC1D71008 CAUTION: Oil gallery bolt XV19S(C)/ XV19M(C)/ When starting the engine make sure the dip- XV19CTS(C)/ XV19CTM(C): stick is securely fitted into the oil tank. 10 Nm (1.0 m·kg, 7.2 ft·lb) 12.Fill: (when engine is disassembled) XV19CS(C)/ XV19C(C): • Crankcase and oil tank 8 Nm (0.8 m·kg, 5.8 ft·lb) (with the specified amount of the recom- mended engine oil)
Page 127: Changing The Transfer Gear Oil
ENGINE 4. Install: • Transfer gear oil check bolt Transfer gear oil check bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) EAS20850 CHANGING THE TRANSFER GEAR OIL 1. Remove: • Muffler • Exhaust pipes 8. Install: Refer to “ENGINE REMOVAL” on page 5-1. •...
Page 128: Bleeding The Hydraulic Clutch System
ENGINE • When refilling, be careful that water does not enter the clutch fluid reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock. ECA13420 CAUTION: Clutch fluid may damage painted surfaces or plastic parts.
Page 129: Checking The Throttle Body Joints
ENGINE EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: • Rider seat • Rider seat bracket assembly Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK”...
Page 130: Checking The Cylinder Head Breather Hose
ENGINE 3. Install: • Air filter case Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. • Rider seat bracket assembly • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21060 CHECKING THE OIL TANK BREATHER HOSE 3.
Page 131: Checking The Exhaust System (For Xv19Cs(C)/ Xv19C(C))
ENGINE 1. Check: EAS1D77002 CHECKING THE EXHAUST SYSTEM (for • Front exhaust pipe “1” XV19CS(C)/ XV19C(C)) • Rear exhaust pipe “2” The following procedure applies to all of the ex- • Muffler “3” haust pipes and gaskets. • Muffler bracket “4” 1.
Page 132: Checking The Canister (For California Only) (For Xv19Sc/ Xv19Mc/ Xv19Ctsc/ Xv19Ctmc)
ENGINE 2. Check: • Canister “1” • Canister hose “2” • Canister purge hose • Canister breather hose “3” • Fuel tank breather/overflow pipe “4” Cracks/damage → Replace. 3. Install: • Horn 1 Refer to “THROTTLE BODIES” on page 6-7. EAS21100 EAS21090 ADJUSTING THE EXUP CABLES...
Page 133 ENGINE c. Tighten both locknuts. L LLL L LLL L LLL L LLL L LLL d. Turn the main switch to “ON” and check that 3. Check: the projection “c” on the EXUP valve pulley • EXUP cable free play (at the EXUP valve pul- contacts the stoppers (fully open and fully ley) “a”...
Page 134: Chassis
CHASSIS EAS21140 EWA13070 CHASSIS WARNING After adjusting the brake pedal position, EAS21190 check that the end of the adjusting bolt “c” is ADJUSTING THE REAR DISC BRAKE visible through the hole “d”. 1. Check: • Brake pedal position (distance “a” from the top of the rider footrest to the top of the brake pedal) Out of specification →...
Page 135: Checking The Front Brake Pads
CHASSIS 2. Remove: ECA13540 CAUTION: • Rider seat Brake fluid may damage painted surfaces Refer to “GENERAL CHASSIS” on page 4-1. and plastic parts. Therefore, always clean up 3. Check: any spilt brake fluid immediately. • Brake fluid level Below the minimum level mark “a” → Add the NOTE: recommended brake fluid to the proper level.
Page 136: Checking The Front Brake Hoses
CHASSIS 3. Check: EAS21280 • Brake hose clamp CHECKING THE FRONT BRAKE HOSES Loose connection → Tighten the clamp bolt. The following procedure applies to all of the 4. Check: brake hoses and brake hose clamps. • Brake hose guide 1.
Page 137: Bleeding The Hydraulic Brake System
CHASSIS L LLL L LLL L LLL L LLL L LLL EAS21350 BLEEDING THE HYDRAULIC BRAKE SYSTEM EWA13100 WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. A.
Page 138: Adjusting The Shift Pedal
CHASSIS b. Turn the shift rod “2” in direction “a” or “b” until EWA13110 WARNING the specified installed shift rod length is ob- After bleeding the hydraulic brake system, tained. check the brake operation. Direction “a” L LLL L LLL L LLL L LLL L LLL...
Page 139: Adjusting The Drive Belt Slack
CHASSIS EAS21430 NOTE: ADJUSTING THE DRIVE BELT SLACK • The level marks of the level window on the low- NOTE: er drive belt cover are in units of 5 mm (0.20 in). The drive belt slack must be checked at the tight- Use them as a standard for measuring the est point on the belt.
Page 140: Checking And Adjusting The Steering Head
CHASSIS 3. Remove: NOTE: • Upper bracket Using the alignment marks on each side of the Refer to “FRONT FORK” on page 4-66. swingarm, make sure that both belt pullers are in 4. Adjust: the same position for proper wheel alignment. •...
Page 141: Checking The Front Fork
CHASSIS EAS21530 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Check: • Inner tube Damage/scratches → Replace. • Oil seal c.
Page 142: Checking The Tires
CHASSIS b. Turn the adjusting ring “3” in direction “a” or c. Tighten the locknut to specification. “b”. Locknut (rear shock absorber spring preload adjusting nut) Direction “a” 30 Nm (3.0 m·kg, 22 ft·lb) Spring preload is increased (suspen- sion is harder). ECA13600 Direction “b”...
Page 143 1.0 mm (0.04 in) Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire EWA14090 WARNING After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires 3-30...
Page 144: Checking The Wheels
• Align the mark “2” with the valve installation en if a tire combination other than one point. approved by Yamaha is used on this vehicle. Front tire Size XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C):...
Page 145: Lubricating The Levers
CHASSIS NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. EAS21700 LUBRICATING THE LEVERS Lubricate the pivoting point and metal-to-metal moving parts of the levers. Recommended lubricant Silicone grease EAS1D77003...
Page 146: Electrical System
ELECTRICAL SYSTEM EAS21750 ELECTRICAL SYSTEM EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 7-67. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 7-67. 5. Replace: • Low beam headlight bulb EAS21790 REPLACING THE HEADLIGHT BULBS (for M MMM M MMM M MMM...
Page 147: Replacing The Headlight Bulb (For Xv19Cs(C)/ Xv19C(C))
ELECTRICAL SYSTEM • Headlight bulb cover “1” 7. Install: • Headlight lens unit 8. Connect: • Air temperature sensor coupler 9. Install: • Headlight cover Headlight cover bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) 10.Install: • Windshield (for XV19CTS(C)/ XV19CTM(C)) b.
Page 148: Adjusting The Headlight Beams
ELECTRICAL SYSTEM 6. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder. ECA13690 CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely A.
Page 149 ELECTRICAL SYSTEM A. For XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C) B. For XV19CS(C)/ XV19C(C) L LLL L LLL L LLL L LLL L LLL 3-36...
Page 150 ELECTRICAL SYSTEM 3-37...
Page 151 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE WINDSHIELD ............... 4-2 ASSEMBLING THE WINDSHIELD ............4-2 INSTALLING THE WINDSHIELD.............. 4-2 REMOVING THE BACKREST ..............4-5 ASSEMBLING THE BACKREST............... 4-5 INSTALLING THE BACKREST ..............4-5 CHECKING THE SIDEBAG BRACKET SPRING NUTS......4-8 FRONT WHEEL..................... 4-18 REMOVING THE FRONT WHEEL............4-22 DISASSEMBLING THE FRONT WHEEL..........
Page 152 REAR BRAKE ....................4-47 INTRODUCTION ..................4-53 CHECKING THE REAR BRAKE DISC............4-53 REPLACING THE REAR BRAKE PADS..........4-53 REMOVING THE REAR BRAKE CALIPER ..........4-54 DISASSEMBLING THE REAR BRAKE CALIPER ........4-54 CHECKING THE REAR BRAKE CALIPER..........4-55 ASSEMBLING THE REAR BRAKE CALIPER ........4-55 INSTALLING THE REAR BRAKE CALIPER...........4-55 REMOVING THE REAR BRAKE MASTER CYLINDER ......
Page 153 BELT DRIVE....................4-90 REMOVING THE DRIVE BELT AND DRIVE PULLEY ......4-92 CHECKING THE DRIVE BELT ...............4-92 INSTALLING THE DRIVE BELT AND DRIVE PULLEY ......4-92...
Page 154: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield (for XV19CTS(C)/ XV19CTM(C)) 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 155: Removing The Windshield
GENERAL CHASSIS ET1D71039 REMOVING THE WINDSHIELD 1. Remove: • Windshield M MMM M MMM M MMM M MMM M MMM a. Insert the key “1” into the windshield lock, turn it clockwise and then remove the key. ET1D71040 INSTALLING THE WINDSHIELD 1.
Page 156 GENERAL CHASSIS c. Insert the key into the windshield lock, turn it counterclockwise until it stops to lock the fas- tener, and then remove the key. 1. Lock 2. Fastener L LLL L LLL L LLL L LLL L LLL...
Page 157 Sidebag (left and right) tions to clean the leather on the sidebags. Polish the dry leather with a soft cloth, and then treat with Yamaha Mink Oil or another high-quality leather protectant for increased water resistance. Backrest assembly...
Page 158: Removing The Backrest
GENERAL CHASSIS ET1D71041 NOTE: REMOVING THE BACKREST Align the projection “a” on the lock “1” with the 1. Remove: slot “b” in the left backrest lower bracket “2”. • Backrest M MMM M MMM M MMM M MMM M MMM a.
Page 159 GENERAL CHASSIS b. Push the rear of the backrest down smoothly but forcefully to lock it in place and make sure that the lever hook “1” on each side is secure- ly fit over its holder “2”. EW1D71017 WARNING Both lever hooks must be securely fitted over their holder.
Page 160 GENERAL CHASSIS Removing the sidebag brackets (for XV19CTS(C)/ XV19CTM(C)) 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 48 Nm (4.8 m kg, 35 ft •...
Page 161: Checking The Sidebag Bracket Spring Nuts
GENERAL CHASSIS ET1D71047 CHECKING THE SIDEBAG BRACKET SPRING NUTS 1. Check: • Sidebag bracket spring nut height “a” Out of specification → Adjust. Sidebag bracket spring nut height 12.0 mm (0.47 in) 2. Check: • Sidebag bracket spring nuts Damage → Replace.
Page 162 GENERAL CHASSIS Removing the seats and side covers 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft •...
Page 163 GENERAL CHASSIS Removing the headlight (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Headlight cover Air temperature sensor coupler Disconnect.
Page 164 GENERAL CHASSIS Removing the headlight (for XV19CS(C)/ XV19C(C)) 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft •...
Page 165 GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Tool kit tray/Seat bracket 4-1. ECU band ECU (electronic control unit) Coupler tray Negative terminal cover Negative battery lead Disconnect. Positive battery lead Disconnect.
Page 166 GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Relay unit Headlight relay Turn signal relay Plastic locking tie Battery box For installation, reverse the removal proce- dure. 4-13...
Page 167 GENERAL CHASSIS Removing the air filter case (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 168 GENERAL CHASSIS Removing the air filter case (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 16 Nm (1.6 m kg, 11 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 169 GENERAL CHASSIS Removing the air filter case (for XV19CS(C)/ XV19C(C)) 10 Nm (1.0 m kg, 7.2 ft 17 Nm (1.7 m kg, 12 ft • • • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 170 GENERAL CHASSIS Removing the air filter case (for XV19CS(C)/ XV19C(C)) 10 Nm (1.0 m kg, 7.2 ft 17 Nm (1.7 m kg, 12 ft • • • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 171: Front Wheel
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • 40 Nm (4.0 m kg, 29 ft •...
Page 172 FRONT WHEEL Removing the front wheel and brake discs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • 40 Nm (4.0 m kg, 29 ft • •...
Page 173 FRONT WHEEL Removing the front wheel and brake discs (for XV19CS(C)/ XV19C(C)) 16 Nm (1.6 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 174 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-21...
Page 175: Removing The Front Wheel
FRONT WHEEL EAS21900 EAS21910 REMOVING THE FRONT WHEEL DISASSEMBLING THE FRONT WHEEL 1. Stand the vehicle on a level surface. 1. Remove: EWA13120 • Oil seals WARNING • Wheel bearings Securely support the vehicle so that there is M MMM M MMM M MMM M MMM...
Page 176: Assembling The Front Wheel
FRONT WHEEL EAS21960 ASSEMBLING THE FRONT WHEEL 1. Install: • Wheel bearings • Oil seals M MMM M MMM M MMM M MMM M MMM a. Install the new wheel bearings and oil seals in the reverse order of disassembly. EC1D71011 CAUTION: Do not contact the wheel bearing inner race...
Page 177: Installing The Front Wheel (Front Brake Discs)
FRONT WHEEL c. Turn the front wheel 90° so that the “X ” mark c. If the heavy spot does not stay in that posi- tion, install a heavier weight. is positioned as shown. d. Repeat steps (b) and (c) until the front wheel d.
Page 178 FRONT WHEEL Front brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) EWA13500 WARNING Make sure the brake hose is routed properly. 7. Install: • Front fender • Left front brake hose guide bracket • Right front brake hose guide bracket 2.
Page 179 FRONT WHEEL 4-26...
Page 180: Rear Wheel
REAR WHEEL EAS22020 REAR WHEEL Removing the rear fender 23 Nm (2.3 m kg, 17 ft 40 Nm (4.0 m kg, 29 ft • • • • 40 Nm (4.0 m kg, 29 ft 23 Nm (2.3 m kg, 17 ft •...
Page 181 REAR WHEEL Removing the rear wheel 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 150 Nm (15.0 m kg, 110 ft • • 27 Nm (2.7 m kg, 19 ft •...
Page 182 REAR WHEEL Removing the rear wheel 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 150 Nm (15.0 m kg, 110 ft • • 27 Nm (2.7 m kg, 19 ft •...
Page 183 REAR WHEEL Removing the rear brake disc and rear wheel drive hub Order Job/Parts to remove Q’ty Remarks Rear brake disc cover Rear brake disc Rear wheel pulley Oil seal Circlip Rear wheel drive hub Circlip Bearing Collar Bearing Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
Page 184 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly pro- cedure. 4-31...
Page 185: Removing The Rear Wheel (Disc)
REAR WHEEL EAS28760 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 186: Checking The Rear Wheel Drive Hub
REAR WHEEL EAS22110 EAS22150 CHECKING THE REAR WHEEL DRIVE HUB ADJUSTING THE REAR WHEEL STATIC 1. Check: BALANCE • Rear wheel drive hub NOTE: Cracks/damage → Replace. • After replacing the tire, wheel or both, the rear • Rear wheel drive hub dampers wheel static balance should be adjusted.
Page 187 REAR WHEEL NOTE: Temporarily tighten the wheel axle nut. 5. Adjust: • Drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK” on page 3-26. 6. Tighten: • Rear wheel axle nut Rear wheel axle nut 150 Nm (15.0 m·kg, 110 ft·lb) 7.
Page 188: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
Page 189 FRONT BRAKE Removing the front brake master cylinder 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 190 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-37...
Page 191 FRONT BRAKE Removing the front brake calipers 40 Nm (4.0 m kg, 29 ft • • 32 Nm (3.2 m kg, 23 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
Page 192 FRONT BRAKE Disassembling the front brake calipers Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw...
Page 193: Introduction
FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA14100 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
Page 194: Replacing The Front Brake Pads
FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Brake pad shims steps until the brake disc deflection is within (onto the brake pads) specification. • Brake pads f. If the brake disc deflection cannot be brought •...
Page 195: Removing The Front Brake Calipers
FRONT BRAKE • Front brake hose “4” NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. L LLL L LLL L LLL L LLL L LLL 3. Install: • Brake pad pin •...
Page 196: Checking The Front Brake Calipers
FRONT BRAKE b. Remove the brake caliper piston seals and EAS22410 ASSEMBLING THE FRONT BRAKE dust seals. CALIPERS L LLL L LLL L LLL L LLL L LLL EWA1D77004 EAS22390 WARNING CHECKING THE FRONT BRAKE CALIPERS • Before installation, all internal brake com- Recommended brake component replace- ponents should be cleaned and lubricated ment schedule...
Page 197: Removing The Front Brake Master Cylinder
FRONT BRAKE • When refilling, be careful that water does ECA14170 CAUTION: not enter the brake fluid reservoir. Water When installing the brake hose onto the will significantly lower the boiling point of brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.
Page 198: Checking The Front Brake Master Cylinder
FRONT BRAKE Recommended fluid DOT 4 EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Front brake master cylinder “1” • Front brake master cylinder holder “2” Front brake master cylinder hold- EAS22500 CHECKING THE FRONT BRAKE MASTER er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) CYLINDER 1.
Page 199 FRONT BRAKE • Turn the handlebar to the left and right to make ECA13540 CAUTION: sure the brake hose does not touch other parts Brake fluid may damage painted surfaces (e.g., wire harness, cables, leads). Correct if and plastic parts. Therefore, always clean up necessary.
Page 200: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper bolt Rear brake caliper Rear brake pad Brake pad spring For installation, reverse the removal proce-...
Page 201 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft •...
Page 202 REAR BRAKE Removing the rear brake master cylinder 7 Nm (0.7 m kg, 5.1 ft • • 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft •...
Page 203 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-50...
Page 204 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. Rear brake hose union bolt Copper washer Rear brake hose...
Page 205 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 206: Introduction
REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA14100 5.5 mm (0.22 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
Page 207: Removing The Rear Brake Caliper
REAR BRAKE Refer to “BLEEDING THE HYDRAULIC NOTE: BRAKE SYSTEM” on page 3-24. Always install new brake pads and brake pad springs as a set. EAS22590 REMOVING THE REAR BRAKE CALIPER M MMM M MMM M MMM M MMM M MMM a.
Page 208: Checking The Rear Brake Caliper
REAR BRAKE b. Remove the brake caliper piston seal and EAS22650 ASSEMBLING THE REAR BRAKE CALIPER dust seal. EWA1D77006 L LLL L LLL L LLL L LLL L LLL WARNING EAS22640 • Before installation, all internal brake com- CHECKING THE REAR BRAKE CALIPER ponents should be cleaned and lubricated Recommended brake component replace- with clean or new brake fluid.
Page 209: Removing The Rear Brake Master Cylinder
REAR BRAKE 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 210: Checking The Rear Brake Master Cylinder
REAR BRAKE EAS22720 EC1D71009 CHECKING THE REAR BRAKE MASTER CAUTION: CYLINDER When installing the brake hose onto the 1. Check: brake master cylinder, make sure the brake • Brake master cylinder pipe touches the projection “a” on the brake Damage/scratches/wear → Replace. caliper bracket as shown.
Page 211 REAR BRAKE 5. Check: • Brake pedal operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-24. 6. Adjust: • Brake pedal position Refer to “ADJUSTING THE REAR DISC BRAKE”...
Page 212: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 28 Nm (2.8 m kg, 20 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 50 Nm (5.0 m kg, 36 ft •...
Page 213 HANDLEBAR Removing the handlebar (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 28 Nm (2.8 m kg, 20 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 50 Nm (5.0 m kg, 36 ft •...
Page 214 HANDLEBAR Removing the handlebar (for XV19CS(C)/ XV19C(C)) 28 Nm (2.8 m kg, 20 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 215 HANDLEBAR Removing the handlebar (for XV19CS(C)/ XV19C(C)) 28 Nm (2.8 m kg, 20 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 23 Nm (2.3 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 216: Removing The Handlebar
HANDLEBAR EAS22860 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” NOTE: 3. Pass the left and right handlebar switch leads Blow compressed air between the handlebar through the handlebar.
Page 217 HANDLEBAR • There should be 1–3 mm (0.04–0.12 in) of EWA13700 WARNING clearance “c” between the throttle grip and the Do not touch the handlebar grip until the rub- grip end. ber adhesive has fully dried. L LLL L LLL L LLL L LLL L LLL...
Page 218 HANDLEBAR Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 4-65...
Page 219: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft • • 19 Nm (1.9 m kg, 13 ft •...
Page 220 FRONT FORK Removing the front fork legs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft • • 115 Nm (11.5 m kg, 85 ft • • 19 Nm (1.9 m kg, 13 ft • • 16 Nm (1.6 m kg, 11 ft •...
Page 221 FRONT FORK Removing the front fork legs (for XV19CS(C)/ XV19C(C)) 7 Nm (0.7 m kg, 5.1 ft • • 19 Nm (1.9 m kg, 13 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
Page 222 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Protector For XV19CS(C)/ XV19C(C) Cap bolt...
Page 223 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks Inner tube bushing Spring Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure.
Page 224: Removing The Front Fork Legs
FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: 3.
Page 225: Checking The Front Fork Legs
FRONT FORK Obstruction → Blow out all of the oil passag- es with compressed air. • Oil flow stopper Damage → Replace. ECA14200 CAUTION: • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material.
Page 226 Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 YM-01442 2. Lubricate: • Inner tube’s outer surface Recommended oil Yamaha fork oil 10WT 3. Install: • Inner tube (in the outer tube) 7. Install: 4. Install: • Oil seal “1”...
Page 227 571.0 cm³ (19.31 US oz) (20.10 Imp.oz) XV19CS(C)/ XV19C(C): 755.0 cm³ (25.53 US oz) (26.58 Imp.oz) Recommended oil Yamaha fork oil 10WT 8. Install: 11.Measure: • Oil seal clip “1” • Front fork leg oil level “a” NOTE: (from the top of the inner tube, with the outer...
Page 228: Installing The Front Fork Legs (For Xv19S(C)/ Xv19M(C)/ Xv19Cts(C)/ Xv19Ctm(C))
FRONT FORK NOTE: Align the groove “a” in the upper front fork cover “1” with the lower front fork cover nut “2”. EAS23050 INSTALLING THE FRONT FORK LEGS (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 6. Tighten: The following procedure applies to both of the •...
Page 229: Installing The Front Fork Legs (For Xv19Cs(C)/ Xv19C(C))
FRONT FORK EAS1D77008 INSTALLING THE FRONT FORK LEGS (for XV19CS(C)/ XV19C(C)) The following procedure applies to both of the front fork legs. 1. Install: • Front fork leg “1” Temporarily tighten the lower bracket pinch bolts and steering stem bolt. NOTE: Make sure the inner tube end is flush with the top of the upper bracket.
Page 230: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1st 52 Nm (5.2 m kg, 37 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 2nd 18 Nm (1.8 m kg, 13 ft •...
Page 231 STEERING HEAD Removing the lower bracket (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1st 52 Nm (5.2 m kg, 37 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 16 Nm (1.6 m kg, 11 ft •...
Page 232 STEERING HEAD Removing the lower bracket (for XV19CS(C)/ XV19C(C)) 7 Nm (0.7 m kg, 5.1 ft • • 165 Nm (16.5 m kg, 120 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 1st 52 Nm (5.2 m kg, 37 ft •...
Page 233 STEERING HEAD Removing the lower bracket (for XV19CS(C)/ XV19C(C)) 7 Nm (0.7 m kg, 5.1 ft • • 165 Nm (16.5 m kg, 120 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 1st 52 Nm (5.2 m kg, 37 ft •...
Page 234: Removing The Lower Bracket
STEERING HEAD b. Remove the bearing race from the lower EAS23110 REMOVING THE LOWER BRACKET bracket with a floor chisel “2” and hammer. 1. Stand the vehicle on a level surface. c. Install a new dust seal and new bearing rac- EWA13120 WARNING ECA14270...
Page 235: Installing The Steering Head (For Xv19Cs(C)/ Xv19C(C))
STEERING HEAD 2. Install: 2. Install: • Lower ring nut “1” • Lower ring nut “1” • Rubber washer “2” • Rubber washer “2” • Upper ring nut “3” • Upper ring nut “3” • Lock washer “4” • Lock washer “4” Refer to “CHECKING AND ADJUSTING Refer to “CHECKING AND ADJUSTING THE STEERING HEAD”...
Page 236: Rear Shock Absorber Assembly And Swingarm
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM ET1D71001 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber assembly and swingarm 48 Nm (4.8 m kg, 35 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 237 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber assembly and swingarm 48 Nm (4.8 m kg, 35 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 7 Nm (0.7 m kg, 5.1 ft • •...
Page 238 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM Removing the rear shock absorber and swingarm 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Parts to remove Q’ty...
Page 239: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Loosen: compressed nitrogen gas. Before handling •...
Page 240: Checking The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM EAS23360 CHECKING THE SWINGARM 1. Check: • Swingarm Bends/cracks/damage → Replace. 2. Check: • Pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. EWA13770 WARNING L LLL L LLL L LLL L LLL L LLL Do not attempt to straighten a bent pivot...
Page 241 REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 2. Install: • Spacer “2” • Bearings “1”, “2”, “3” EC1D71010 CAUTION: (to the relay arm) When inserting the spacer into the connect- • Oil seals “4”, “5” ing arms and the rear shock absorber, be (to the relay arm) careful not to damage the bushings and O- Installed depth “a”...
Page 242: Installing The Swingarm
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM 6. Tighten: 2. Swingarm • Connecting-arm-to-relay-arm nut A. Left side B. Right side Connecting-arm-to-relay-arm nut 3. Install: 59 Nm (5.9 m·kg, 43 ft·lb) • Pivot shaft • Rear-shock-absorber-assembly-to-relay-arm • Washer • Pivot shaft nut NOTE: Rear-shock-absorber-assembly- Temporarily tighten the pivot shaft nut.
Page 243: Belt Drive
BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt and drive pulley 10 Nm (1.0 m kg, 7.2 ft 53 Nm (5.3 m kg, 38 ft • • • • 63 Nm (6.3 m kg, 45 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 244 BELT DRIVE Removing the drive belt and drive pulley 10 Nm (1.0 m kg, 7.2 ft • • 53 Nm (5.3 m kg, 38 ft • • 63 Nm (6.3 m kg, 45 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 245 BELT DRIVE • The drive belt can not be bent smaller than EAS23520 REMOVING THE DRIVE BELT AND DRIVE 127 mm (5 in) “a”. PULLEY • The removed drive belt can not be twisted NOTE: inside out. Loosen the drive pulley nut before removing the rear wheel.
Page 246 BELT DRIVE 3. Install: • Swingarm • Rear shock absorber Refer to “REAR SHOCK ABSORBER AS- SEMBLY AND SWINGARM” on page 4-83. • Rear wheel Refer to “REAR WHEEL” on page 4-27. 4. Tighten: • Drive pulley nut Drive pulley nut 140 Nm (14.0 m·kg, 100 ft·lb) NOTE: •...
Page 247 ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE SHIFT PEDAL ASSEMBLY......... 5-8 CHECKING THE OIL COOLER (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) ..............5-10 REMOVING THE ENGINE ..............5-15 INSTALLING THE ENGINE..............5-15 CAMSHAFTS....................5-17 REMOVING THE CYLINDER HEAD COVERS ........5-24 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS .............5-24 REMOVING THE CAMSHAFTS..............5-24 CHECKING THE CAMSHAFTS ..............5-26...
Page 248 CLUTCH ......................5-53 REMOVING THE CLUTCH ..............5-64 REMOVING THE PRIMARY DRIVE GEAR ..........5-64 REMOVING THE LEFT BALANCER DRIVE GEAR .......5-64 CHECKING THE FRICTION PLATES.............5-65 CHECKING THE CLUTCH PLATES ............5-65 CHECKING THE CLUTCH SPRING PLATE...........5-65 CHECKING THE CLUTCH HOUSING ............5-66 CHECKING THE CLUTCH BOSS............5-66 CHECKING THE PRESSURE PLATE ............5-66 CHECKING THE CLUTCH PUSH RODS ..........
Page 249 CRANKCASE ....................5-94 DISASSEMBLING THE CRANKCASE............5-97 CHECKING THE CRANKCASE ..............5-97 CHECKING THE BEARINGS AND OIL SEAL ........5-97 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE ......5-97 CHECKING THE OIL STRAINERS ............5-97 CHECKING THE ENGINE OIL PUMP DRIVEN GEAR......5-97 INSTALLING THE BEARING RETAINERS..........
Page 250: Engine Removal
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipes (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft • • 29 Nm (2.9 m kg, 21 ft • • 53 Nm (5.3 m kg, 38 ft •...
Page 251 ENGINE REMOVAL Removing the muffler and exhaust pipes (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 10 Nm (1.0 m kg, 7.2 ft • • 29 Nm (2.9 m kg, 21 ft • • 53 Nm (5.3 m kg, 38 ft • • 24 Nm (2.4 m kg, 17 ft •...
Page 252 ENGINE REMOVAL Removing the muffler and exhaust pipes (for XV19CS(C)/ XV19C(C)) 29 Nm (2.9 m kg, 21 ft 20 Nm (2.0 m kg, 14 ft • • • • 53 Nm (5.3 m kg, 38 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 253 ENGINE REMOVAL Removing the cylinder-#1 ignition coils and sidestand (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
Page 254 ENGINE REMOVAL Removing the cylinder-#1 ignition coils and sidestand (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
Page 255 ENGINE REMOVAL Removing the right ignition coils and sidestand (for XV19CS(C)/ XV19C(C)) 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 63 Nm (6.3 m kg, 45 ft •...
Page 256 ENGINE REMOVAL Removing the right ignition coils and sidestand (for XV19CS(C)/ XV19C(C)) 7 Nm (0.7 m kg, 5.1 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 63 Nm (6.3 m kg, 45 ft •...
Page 257: Installing The Shift Pedal Assembly
ENGINE REMOVAL ET1D71029 INSTALLING THE SHIFT PEDAL ASSEMBLY 1. Assemble: (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) • Shift pedal (heel side) “1” • Shift pedal (toe side) “2” Shift pedal (heel side) bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) NOTE: Align the mark “a” on the pin on the toe side with the mark “b”...
Page 258 ENGINE REMOVAL Removing the oil cooler and oil filter bracket 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 17 Nm (1.7 m kg, 12 ft •...
Page 259: Checking The Oil Cooler (For Xv19S(C)/ Xv19M(C)/ Xv19Cts(C)/ Xv19Ctm(C))
ENGINE REMOVAL ET1D71028 CHECKING THE OIL COOLER (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Check: • Oil cooler fins Obstruction → Clean. Apply compressed air to the rear of the oil cooler. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver.
Page 260 ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft 7 Nm (0.7 m kg, 5.1 ft • • • •...
Page 261 ENGINE REMOVAL Disconnecting the leads 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft 7 Nm (0.7 m kg, 5.1 ft • • • •...
Page 262 ENGINE REMOVAL Removing the engine A 105 Nm (10.5 m kg, 75 ft • • A 59 Nm (5.9 m kg, 43 ft 53 Nm (5.3 m kg, 38 ft • • • • B 90 Nm (9.0 m kg, 65 ft •...
Page 263 ENGINE REMOVAL Removing the engine A 105 Nm (10.5 m kg, 75 ft • • A 59 Nm (5.9 m kg, 43 ft 53 Nm (5.3 m kg, 38 ft • • • • B 90 Nm (9.0 m kg, 65 ft •...
Page 264: Removing The Engine
ENGINE REMOVAL 3. Tighten: ET1D71019 REMOVING THE ENGINE • Spacer bolt “1” 1. Loosen: • Spacer bolt Spacer bolt 18 Nm (1.8 m·kg, 13 ft·lb) NOTE: Loosen the spacer bolt with the pivot shaft NOTE: wrench “1”. • Tighten the spacer bolt “1” to specification with a pivot shaft wrench.
Page 265 ENGINE REMOVAL NOTE: Engine mounting nut (rear lower To install and route the leads, refer to “CABLE side) ROUTING (for XV19S(C)/ XV19M(C)/ 98 Nm (9.8 m·kg, 71 ft·lb) XV19CTS(C)/ XV19CTM(C))” on page 2-51 and Engine mounting nut (front lower “CABLE ROUTING (for XV19CS(C)/ side) XV19C(C))”...
Page 266: Camshafts
CAMSHAFTS EAS23750 CAMSHAFTS Removing the camshaft sprocket cover 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 267 CAMSHAFTS Removing the cylinder head covers 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head breather hose Oil tank breather hose Disconnect. Wire harness guide Fuel tank damper Fuel outlet hose Disconnect.
Page 268 CAMSHAFTS Removing the push rods and rocker arms 10 Nm (1.0 m kg, 7.2 ft 24 Nm (2.4 m kg, 17 ft • • • • 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft •...
Page 269 CAMSHAFTS Removing the valve lifters 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “CYLINDERS AND PISTONS” on Front cylinder page 5-48. Push rod cover O-ring O-ring Seal...
Page 270 CAMSHAFTS Removing the camshafts and right balancer 40 Nm (4.0 m kg, 29 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft 60 Nm (6.0 m kg, 43 ft •...
Page 271 CAMSHAFTS Removing the camshafts and right balancer 40 Nm (4.0 m kg, 29 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft 60 Nm (6.0 m kg, 43 ft •...
Page 272 CAMSHAFTS Disassembling the camshafts Order Job/Parts to remove Q’ty Remarks Circlip Washer Decompression cam spring Decompression cam Decompression pin Front cylinder camshaft Rear cylinder camshaft For assembly, reverse the disassembly pro- cedure. 5-23...
Page 273: Removing The Cylinder Head Covers
CAMSHAFTS ET1D71030 REMOVING THE CYLINDER HEAD COVERS 1. Remove: • Front cylinder • Rear cylinder “1” NOTE: Due to the small clearance between the frame and the rear cylinder head cover, the three bolts “2” cannot be removed when the cover is in place.
Page 274 CAMSHAFTS NOTE: • Place a folded copper washer “3” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them. • Place a folded copper washer “4” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them.
Page 275: Checking The Camshafts
CAMSHAFTS EAS23860 CHECKING THE CAMSHAFTS 1. Check: • Cam Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Cam dimensions A “a” and B “b” Out of specification → Replace the camshaft. Camshaft lobe dimensions 3. Measure: Intake A •...
Page 276: Checking The Rocker Arms And Rocker Arm Shafts
CAMSHAFTS NOTE: Calculate the clearance by subtracting the cam- shaft journal diameter (crankcase side) from the crankcase hole inside diameter. Camshaft to crankcase clearance 0.020–0.064 mm (0.0008–0.0025 8. Calculate: 5. Measure: • Camshaft to camshaft cover clearance • Crankcase hole inside diameter “a” Out of specification →...
Page 277: Checking The Rocker Arm Bases
CAMSHAFTS • Push rod end Bends/damage → Replace. 2. Measure: • Push rod runout Out of specification → Replace. Valve push rod runout 0.3 mm (0.012 in) 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification → Replace. Rocker arm shaft outside diame- 17.976–17.991 mm (0.7077–...
Page 278: Checking The Push Rod Cover
CAMSHAFTS Valve lifter outside diameter (in- Valve-lifter-to-valve-lifter-hole take) clearance 22.962–22.974 mm (0.9040– 0.026–0.059 mm (0.0010–0.0023 0.9045 in) Valve lifter outside diameter (ex- haust) EAS23930 CHECKING THE PUSH ROD COVER 22.962–22.974 mm (0.9040– 0.9045 in) 1. Check: • Push rod cover Cranks/damage →...
Page 279: Checking The Oil Delivery Pipe
CAMSHAFTS 2. Install: • Camshaft cover 1 “1” • Oil delivery pipe 1 “2” NOTE: Tighten the camshaft cover bolts in stages and in a crisscross pattern. 2. Measure: • Compressed decompression cam spring force “a” Out of specification → Replace the decom- pression cam spring.
Page 280 CAMSHAFTS • Place a folded copper washer “3” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them. • Place a folded copper washer “4” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them.
Page 281: Bleeding A Valve Lifter
CAMSHAFTS NOTE: • Cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase. • Align the punch mark “a” on the camshaft driv- en gear “1” with the punch mark “b” on the camshaft drive gear “2”.
Page 282: Installing The Valve Lifters
CAMSHAFTS NOTE: The crankshaft can be rotated smoothly when the spark plugs are removed. EWA12880 WARNING Be careful since the engine is hot. g. With piston #1 at TDC, count the indicated number of gear teeth and place marks “2” through “5”...
Page 283: Installing The Rocker Arms And Push Rods
CAMSHAFTS M MMM M MMM M MMM M MMM M MMM a. Put the rocker arm base on the cylinder head. b. Install the push rods. NOTE: • Be sure to correctly install the push rods be- tween the rocker arms and valve lifters as shown.
Page 284: Installing The Cylinder Head Covers
CAMSHAFTS Bolts “2”: l = 45 mm (1.77 in) ET1D71032 INSTALLING THE SHIFT PEDAL ASSEMBLY Bolts “3”: l = 70 mm (2.76 in) (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 1. Install: • Shift pedal assembly “1” NOTE: Align the mark “a” on the shift pedal shaft with the slot in the shift pedal.
Page 285: Cylinder Heads
CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 53 Nm (5.3 m kg, 38 ft • • 66 Nm (6.6 m kg, 48 ft • • 20 Nm (2.0 m kg, 14 ft • • 53 Nm (5.3 m kg, 38 ft •...
Page 286 CYLINDER HEADS Removing the cylinder heads 53 Nm (5.3 m kg, 38 ft • • 66 Nm (6.6 m kg, 48 ft • • 20 Nm (2.0 m kg, 14 ft • • 53 Nm (5.3 m kg, 38 ft •...
Page 287: Removing The Cylinder Heads
CYLINDER HEADS EAS24140 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head nuts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. 2.
Page 288: Installing The Cylinder Heads
CYLINDER HEADS EAS24250 INSTALLING THE CYLINDER HEADS 1. Install: • Cylinder head gasket “1” • Dowel pins “2” NOTE: The “1D7” mark on the cylinder head gasket must face up and towards the left side of the cyl- inder. A. Front cylinder B.
Page 289 CYLINDER HEADS Engine mounting bolt (right up- per side) XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C): 59 Nm (5.9 m·kg, 43 ft·lb) XV19CS(C)/ XV19C(C): 66 Nm (6.6 m·kg, 48 ft·lb) Engine mounting bolt (left upper side) 66 Nm (6.6 m·kg, 48 ft·lb) LOCTITE® Engine bracket bolt (right upper side) 53 Nm (5.3 m·kg, 38 ft·lb)
Page 290 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-36. Valve cotter Upper spring seat Valve spring Intake valve...
Page 291: Valves And Valve Springs
VALVES AND VALVE SPRINGS 3. Remove: EAS24280 REMOVING THE VALVES • Upper spring seat “1” The following procedure applies to all of the • Valve spring “2” valves and related components. • Valve “3” NOTE: • Valve stem seal “4” Before removing the internal parts of the cylinder •...
Page 292 VALVES AND VALVE SPRINGS c. After installing the valve guide, bore the valve guide with the valve guide reamer “3” to ob- tain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) 2.
Page 293: Checking The Valve Seats
VALVES AND VALVE SPRINGS Valve seat width C (intake) 1.10–1.30 mm (0.0433–0.0512 in) Limit 2.0 mm (0.08 in) Valve seat width C (exhaust) 1.10–1.30 mm (0.0433–0.0512 in) Limit 2.0 mm (0.08 in) 6. Measure: • Valve stem runout Out of specification → Replace the valve. NOTE: •...
Page 294: Checking The Valve Springs
VALVES AND VALVE SPRINGS g. Apply Mechanic’s blueing dye (Dykem) “b” ECA13790 CAUTION: onto the valve face. Do not let the lapping compound enter the gap between the valve stem and the valve guide. h. Install the valve into the cylinder head. i.
Page 295: Installing The Valves
VALVES AND VALVE SPRINGS 2. Measure: EAS24340 INSTALLING THE VALVES • Compressed valve spring force “a” Out of specification → Replace the valve The following procedure applies to all of the valves and related components. spring. 1. Deburr: Installed compression spring •...
Page 296 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve NOTE: stem, lightly tap the valve tip with a soft-face • Make sure each valve is installed in its original hammer. place. ECA13800 • Install the valve springs with the larger pitch “a” CAUTION: facing up.
Page 297 CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-36. Front cylinder Rear cylinder Cylinder gasket Dowel pin Circlip Piston pin Piston Top ring 2nd ring Oil ring For installation, reverse the removal proce-...
Page 298: Cylinders And Pistons
CYLINDERS AND PISTONS EAS24380 NOTE: REMOVING THE PISTON When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring • Piston pin clips “1” over the piston crown. • Piston pin “2” •...
Page 299: Checking The Piston Rings
CYLINDERS AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.
Page 300: Checking The Piston Pins
CYLINDERS AND PISTONS 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring 3.
Page 301 CYLINDERS AND PISTONS 3. Lubricate: NOTE: • Piston Be sure to install the piston rings so that the • Piston rings manufacturer’s marks or numbers face up. • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 4. Offset: • Piston ring end gaps 90 ˚...
Page 302: Clutch
CLUTCH EAS25060 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft (11) • • • • Order Job/Parts to remove Q’ty Remarks Drain.
Page 303 CLUTCH Removing the clutch cover 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft (11) • • • • Order Job/Parts to remove Q’ty Remarks Clutch cover Clutch cover gasket Dowel pin For installation, reverse the removal proce-...
Page 304 CLUTCH Removing the crankshaft position sensor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil seal Bearing Clutch cover damper plate Clutch cover damper Crankshaft position sensor lead holder Crankshaft position sensor For installation, reverse the removal proce- dure.
Page 305 CLUTCH Removing the clutch 26 25 105 Nm (10.5 m kg, 75 ft • • 15 14 13 12 100 Nm (10.0 m kg, 72 ft • • 85 Nm (8.5 m kg, 61 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 306 CLUTCH Removing the clutch 26 25 105 Nm (10.5 m kg, 75 ft • • 15 14 13 12 100 Nm (10.0 m kg, 72 ft • • 85 Nm (8.5 m kg, 61 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 307 CLUTCH Removing the clutch 26 25 105 Nm (10.5 m kg, 75 ft • • 15 14 13 12 100 Nm (10.0 m kg, 72 ft • • 85 Nm (8.5 m kg, 61 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
Page 308 CLUTCH Removing the left balancer 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks Left balancer idle gear shaft holder Dowel pin O-ring Left balancer idle gear...
Page 309 CLUTCH Removing the clutch master cylinder 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-15. Left rearview mirror Clutch master cylinder reservoir cap Clutch master cylinder reservoir diaphragm...
Page 310 CLUTCH Disassembling the clutch master cylinder Order Job/Parts to remove Q’ty Remarks Clutch master cylinder push rod Dust boot Circlip Washer Clutch master cylinder kit Clutch master cylinder body For assembly, reverse the disassembly pro- cedure. 5-61...
Page 311 CLUTCH Removing the clutch release cylinder 19 Nm (1.9 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 312 CLUTCH Disassembling the clutch release cylinder 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Boots Clutch release cylinder piston Clutch release cylinder spring Clutch release cylinder piston seal Bleed screw Clutch release cylinder body For assembly, reverse the disassembly pro- cedure.
Page 313: Removing The Clutch
CLUTCH EAS25080 REMOVING THE CLUTCH Sheave holder 1. Loosen: 90890-01701 • Clutch boss nut “1” Primary clutch holder YS-01880-A NOTE: While holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. Universal clutch holder 90890-04086 YM-91042 2.
Page 314: Checking The Friction Plates
CLUTCH A. Friction plate 1, 3 EAS25100 CHECKING THE FRICTION PLATES B. Friction plate 2 The following procedure applies to all of the fric- tion plates. EAS25110 CHECKING THE CLUTCH PLATES 1. Check: The following procedure applies to all of the •...
Page 315: Checking The Clutch Housing
CLUTCH 2. Check: • Bearing Damage/wear → Replace. • Clutch spring plate seat Damage → Replace. EAS25190 CHECKING THE CLUTCH PUSH RODS EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: 1. Check: • O-ring • Clutch housing dogs • Short clutch push rod Damage/pitting/wear →...
Page 316: Installing The Left Balancer Drive Gear
CLUTCH • Left balancer idle gear NOTE: Burrs/chips/roughness/wear → Replace the Calculate the clearance by subtracting the left defective part(s). balancer driven gear housing outside diameter 2. Measure: from the left balancer driven gear inside diame- • Left balancer driven gear inside diameter “a” ter.
Page 317: Installing The Primary Drive Gear
CLUTCH L LLL L LLL L LLL L LLL L LLL 4. Install: • Generator rotor Refer to “INSTALLING THE GENERATOR” on page 5-80. 5. Install: • Left balancer drive gear “1” • Left balancer idle gear “2” • Left balancer driven gear “3” NOTE: •...
Page 318: Installing The Clutch
CLUTCH • Washer • Conical spring washer “2” • Clutch boss nut “3” Clutch boss nut 105 Nm (10.5 m·kg, 75 ft·lb) NOTE: • Lubricate the clutch boss nut threads and con- ical spring washer mating surfaces with engine oil. •...
Page 319: Disassembling The Clutch Master Cylinder
(onto the crankshaft position sensor lead To collect any remaining clutch fluid, place a grommet) container under the master cylinder and the end of the clutch hose. Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) ET1D71037 CHECKING THE CLUTCH MASTER CYLINDER 8.
Page 320: Assembling The Clutch Master Cylinder
CLUTCH • Clutch master cylinder reservoir diaphragm EWA1D77010 WARNING Damage/wear → Replace. Proper clutch hose routing is essential to in- 4. Check: sure safe vehicle operation. Refer to “CABLE • Clutch hose Cracks/damage/wear → Replace. ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))” on page 2-51 EAS25300 and “CABLE ROUTING (for XV19CS(C)/ ASSEMBLING THE CLUTCH MASTER...
Page 321: Removing The Clutch Release Cylinder
CLUTCH EWA13370 ET1D71004 REMOVING THE CLUTCH RELEASE WARNING CYLINDER • Use only the designated clutch fluid. Other 1. Remove: clutch fluids may cause the rubber seals to • Clutch pipe union bolt “1” deteriorate, causing leakage and poor • Copper washers “2” clutch performance.
Page 322: Assembling The Clutch Release Cylinder
CLUTCH 2. Fill: EAS25340 ASSEMBLING THE CLUTCH RELEASE • Clutch master cylinder reservoir CYLINDER (with the specified amount of the recom- EW1D71006 mended clutch fluid) WARNING • Before installation, all internal clutch com- Recommended clutch fluid ponents must be cleaned and lubricated Brake fluid DOT 4 with clean or new clutch fluid.
Page 323 CLUTCH 5. Check: • Clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” on page 3-15. 5-74...
Page 324: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Clutch housing Refer to “CLUTCH” on page 5-53. Washer Circlip Shift shaft...
Page 325: Checking The Shift Shaft
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
Page 326: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 327 GENERATOR AND STARTER CLUTCH Removing the generator rotor 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 80 Nm (8.0 m kg, 58 ft • • Order Job/Parts to remove Q’ty Remarks Torque limiter Starter clutch idle gear shaft...
Page 328: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 NOTE: REMOVING THE GENERATOR While holding the generator rotor “1” with the 1. Remove: sheave holder “2”, loosen the starter clutch • Generator rotor bolt “1” bolts. • Washer NOTE: Sheave holder While holding the generator rotor “2” with the 90890-01701 sheave holder “3”, loosen the generator rotor Primary clutch holder...
Page 329: Checking The Torque Limiter
Primary clutch holder 90890-01701 YS-01880-A Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the stator coil lead grommet) EAS24510 INSTALLING THE GENERATOR 1. Install: Yamaha bond No. 1215 • Woodruff key 90890-85505 (Three Bond No.1215®) • Generator rotor “1” 5-80...
Page 330 GENERATOR AND STARTER CLUTCH 5-81...
Page 331: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Starter motor For installation, reverse the removal proce- dure. 5-82...
Page 332 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor front cover Bearing Oil seal Circlip Starter motor rear cover Brush Brush holder (along with the brushes) Brush seat (along with the brushes) Bearing Gasket Armature assembly Starter motor yoke For assembly, reverse the disassembly pro- cedure.
Page 333: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “a” Armature coil Out of specification → Replace the starter Commutator resistance “1”...
Page 334: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearings • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Starter motor yoke “1” NOTE: Align the projection “a” on the brush holder with the slot “b”...
Page 335: Transfer Gear Case
TRANSFER GEAR CASE EAS25460 TRANSFER GEAR CASE Removing the middle driven shaft 18 Nm (1.8 m kg, 13 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 336 TRANSFER GEAR CASE Removing the middle driven shaft 18 Nm (1.8 m kg, 13 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 337 TRANSFER GEAR CASE Disassembling the transfer gear oil pump ( 6 ) 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Parts to remove Q’ty Remarks Transfer gear oil pump cover Transfer gear oil pump outer rotor Transfer gear oil pump inner rotor Washer Transfer gear oil pump shaft Transfer gear oil pump housing...
Page 338 TRANSFER GEAR CASE Removing the transfer gear case 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 50 Nm (5.0 m kg, 36 ft •...
Page 339 TRANSFER GEAR CASE Disassembling the oil tank 28 Nm (2.8 m kg, 20 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (15) 10 Nm (1.0 m kg, 7.2 ft •...
Page 340: Removing The Middle Driven Shaft
TRANSFER GEAR CASE 2. Check: EAS25470 REMOVING THE MIDDLE DRIVEN SHAFT • Primary chain NOTE: Damage/stiffness → Replace the primary Loosen the middle drive gear nut before remove chain, middle drive gear and middle driven the drive pulley. shaft as a set. 1.
Page 341: Checking The Oil Pipes
TRANSFER GEAR CASE • Transfer gear oil pump cover “7” Inner-rotor-to-outer-rotor-tip NOTE: clearance When installing the inner rotor, align the pin in Less than 0.12 mm (0.0047 in) the oil pump shaft with the groove in the inner ro- Limit tor.
Page 342 TRANSFER GEAR CASE • Install the middle driven shaft, middle drive 4. Remove: gear and primary chain at the same time. • Drive pulley nut • Align the splines on the middle drive gear with the splines on the drive axle. •...
Page 343: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
Page 344 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft •...
Page 345 CRANKCASE Removing the oil seals and bearings 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • A 10 Nm (1.0 m kg, 7.2 ft • • B 12 Nm (1.2 m kg, 8.7 ft •...
Page 346: Disassembling The Crankcase
CRANKCASE EAS25570 DISASSEMBLING THE CRANKCASE 1. Remove: • Crankcase bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. •...
Page 347: Installing The Bearing Retainers
• Sealant 10 Nm (1.0 m·kg, 7.2 ft·lb) (onto the crankcase mating surfaces) Crankcase bolt (M8) 24 Nm (2.4 m·kg, 17 ft·lb) Yamaha bond No. 1215 90890-85505 NOTE: (Three Bond No.1215®) • Lubricate the bolt threads with engine oil. • Tighten each bolt 1/4 of a turn at a time, in stag- NOTE: es and in a crisscross pattern.
Page 348 CRANKCASE 14 19 20 16 15 A. Right crankcase B. Left crankcase 5. Apply: • Engine oil (onto the crankshaft pin bearings and oil de- livery holes) 6. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-99...
Page 349: Oil Pump
OIL PUMP EAS24910 OIL PUMP Removing the oil pump 24 Nm (2.4 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Oil pump assembly For installation, reverse the removal proce- dure.
Page 350 OIL PUMP Disassembling the oil pump 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Oil pump housing cover 1 Oil scavenging pump outer rotor 1 Oil scavenging pump inner rotor 1 Oil pump housing 1 Oil strainer...
Page 351 OIL PUMP Disassembling the oil pump 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Oil pump shaft Oil seal Circlip Oil seal Ball Ball guide Oil pump housing 2 For assembly, reverse the disassembly pro- cedure.
Page 352: Checking The Oil Pump
OIL PUMP 3. Check: EAS24960 CHECKING THE OIL PUMP • Oil pump operation 1. Check: Rough movement → Repeat steps (1) and • Oil pump housing (2) or replace the defective part(s). • Oil pump housing cover Cracks/damage/wear → Replace the defec- tive part(s).
Page 353: Checking The Oil Strainer
OIL PUMP 2. Measure: • Oil pump shaft • Ball spring force (with the recommended lubricant) • Relief valve spring force Recommended lubricant Out of specification → Replace the defective Engine oil part(s). 2. Install: Ball spring • Oil pump housing 2 “1” Installed compression spring •...
Page 354: Installing The Oil Pump
OIL PUMP 14 21 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-103. EAS25020 INSTALLING THE OIL PUMP 1. Install: • Oil pump assembly “1” Oil pump assembly bolt 24 Nm (2.4 m·kg, 17 ft·lb) ECA13890 CAUTION: After tightening the bolts, make sure the oil...
Page 355 CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.
Page 356: Crankshaft
CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS 1. Remove: • Connecting rod caps “1” • Connecting rods • Big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. 3. Measure: •...
Page 357 CRANKSHAFT d. Assemble the connecting rod halves. h. Tighten the connecting rod bolts further to reach the specified angle 125–135°. NOTE: • Do not move the connecting rod or crankshaft Connecting rod bolt (final) until the clearance measurement has been Specified angle 125–135°...
Page 358 CRANKSHAFT For example, if the connecting rod “P ” and the crankshaft web “P” numbers are “5” and “2” respectively, then the bearing size for “P ” “P ” (connecting rod) - “P” (crankshaft) 5 - 2 = 3 (brown) Bearing color code 1.Blue 2.Black 3.Brown 4.Green L LLL...
Page 359: Installing The Connecting Rods
CRANKSHAFT EAS26150 INSTALLING THE CONNECTING RODS 1. Lubricate: • Bolt threads (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 2. Lubricate: • Crankshaft pins 4. Tighten: • Big end bearings • Connecting rod bolts “1” • Connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil...
Page 360: Installing The Crankshaft Assembly
CRANKSHAFT NOTE: • Make sure that the generator shaft drive gear teeth and generator shaft driven gear teeth mesh correctly. • Align the punch mark “a” on the generator shaft driven gear with the punch mark “b” on the gen- erator shaft drive gear.
Page 361 TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-94. Shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Drive axle assembly Main axle assembly Spacer For installation, reverse the removal proce-...
Page 362 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Collar Toothed washer Circlip 3rd pinion gear Circlip Toothed washer 4th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
Page 363 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Washer 1st wheel gear Collar 4th wheel gear Circlip Toothed washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 5th wheel gear Circlip Toothed washer 2nd wheel gear Collar 5-114...
Page 364: Transmission
TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Drive axle For assembly, reverse the disassembly pro- cedure. 5-115...
Page 365: Checking The Shift Forks
TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. • Shift drum groove Damage/scratches/wear → Replace the shift 1. Check: • Shift fork cam follower “1” drum assembly.
Page 366: Assembling The Main Axle And Drive Axle
TRANSMISSION 3. Check: • Transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s). • Transmission gear dogs Cracks/damage/rounded edges → Replace the defective gear(s). 2. Install: • Toothed lock washer retainer “1” • Toothed lock washer “2” NOTE: • With the toothed lock washer retainer “1” in the groove “a”...
Page 367 TRANSMISSION NOTE: The embossed marks “1D7” on the shift forks should face towards the left side of the engine. 2. Check: • Transmission Rough movement → Repair. NOTE: • Apply engine oil to each gear and bearing thor- oughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely.
Page 368 TRANSMISSION 5-119...
Page 369 FUEL SYSTEM FUEL TANK..................... 6-1 REMOVING THE FUEL TANK ..............6-4 REMOVING THE FUEL PUMP ..............6-4 CHECKING THE FUEL PUMP BODY............6-5 CHECKING THE FUEL PUMP OPERATION..........6-5 INSTALLING THE FUEL PUMP..............6-5 INSTALLING THE FUEL TANK..............6-5 THROTTLE BODIES ..................6-7 REMOVING THE FUEL HOSE ...............6-15 CHECKING THE INJECTORS ..............6-15 CHECKING THE THROTTLE BODIES...........6-15 CHECKING THE ROLLOVER VALVES..........
Page 370 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 371 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 372 FUEL TANK Removing the fuel pump and sub-fuel tank 5 Nm (0.5 m kg, 3.6 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Rider seat bracket 4-1.
Page 373: Removing The Fuel Tank
FUEL TANK EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel tank EC1D71021 CAUTION: Although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain- d.
Page 374: Checking The Fuel Pump Body
FUEL TANK • Install the fuel pump as shown in the illustra- EC1D71022 CAUTION: tion. • Be sure to disconnect the fuel outlet hose • Align the projection “a” on the fuel pump with by hand. Do not forcefully disconnect the the slot in the fuel pump bracket.
Page 375 FUEL TANK b. Remove the fuel hose joint caps. c. Connect the fuel hose (fuel hose joint to fuel pump) and air vent hose (fuel pump to fuel hose joint). d. Turn the screws “1” counterclockwise. NOTE: Turn the screws until they contact the clips “a”. e.
Page 376: Throttle Bodies
THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the rollover valves (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks For California only Horn 1 connector Disconnect.
Page 377 THROTTLE BODIES Removing the rollover valves (for XV19CS/ XV19C) 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank Refer to “FUEL TANK” on page 6-1. Refer to “GENERAL CHASSIS”...
Page 378 THROTTLE BODIES Removing the rollover valves (for california only) (for XV19CSC/ XV19CC) 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 379 THROTTLE BODIES Removing the pressure regulator (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Pressure regulator cover...
Page 380 THROTTLE BODIES Removing the left ignition coils and pressure regulator (for XV19CS(C)/ XV19C(C)) 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 381 THROTTLE BODIES Removing the throttle bodies 3 Nm (0.3 m kg, 2.2 ft • • 3 Nm (0.3 m kg, 2.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Rider seat bracket 4-1.
Page 382 THROTTLE BODIES Removing the intake manifolds 10 Nm (1.0 m kg, 7.2 ft • • ( 2 ) ( 2 ) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Engine temperature sensor coupler Disconnect.
Page 383 THROTTLE BODIES Disassembling the intake manifolds 30 Nm (3.0 m kg, 22 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder-#1 injector coupler Disconnect.
Page 384: Removing The Fuel Hose
THROTTLE BODIES b. Blow out all of the passages with compressed ET1D71026 REMOVING THE FUEL HOSE air. 1. Disconnect: L LLL L LLL L LLL L LLL L LLL • Fuel hose (intake manifold assembly to pres- sure regulator) ET1D71007 CHECKING THE ROLLOVER VALVES EC1D71014 1.
Page 385: Installing The Fuel Pipe
THROTTLE BODIES EAS27030 ADJUSTING THE THROTTLE POSITION Vacuum/pressure pump gauge SENSOR 1. Check: 90890-06756 Mityvac brake bleeding tool • Throttle position sensor YS-42423 Refer to “CHECKING THE THROTTLE PO- Pressure gauge SITION SENSOR” on page 7-89. 90890-03153 2. Adjust: YU-03153 •...
Page 386: Installing The Fuel Hose
THROTTLE BODIES Fuel pipe bolt 30 Nm (3.0 m·kg, 22 ft·lb) NOTE: Install the fuel pipe “1” so that it contacts the pro- jections “a” on the injector joints. ET1D71027 INSTALLING THE FUEL HOSE 1. Connect: • Fuel hose (intake manifold assembly to pres- sure regulator) EC1D71015 CAUTION:...
Page 387: Isc (Idle Speed Control) Unit
ISC (IDLE SPEED CONTROL) UNIT ET1D71009 ISC (IDLE SPEED CONTROL) UNIT Removing the ISC (idle speed control) unit 7 Nm (0.7 m kg, 5.1 ft 7 Nm (0.7 m kg, 5.1 ft • • • • 7 Nm (0.7 m kg, 5.1 ft •...
Page 388: Checking The Isc (Idle Speed Control) System
ISC (IDLE SPEED CONTROL) UNIT ET1D71010 CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM 1. Check: • Hoses Loose connections → Connect properly. Cracks/damage → Replace. 6-19...
Page 389 ELECTRICAL SYSTEM IGNITION SYSTEM ..................7-1 CIRCUIT DIAGRAM .................. 7-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION.......7-3 TROUBLESHOOTING ................7-4 ELECTRIC STARTING SYSTEM ..............7-7 CIRCUIT DIAGRAM .................. 7-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......7-9 TROUBLESHOOTING ................7-11 CHARGING SYSTEM..................7-13 CIRCUIT DIAGRAM ................7-13 TROUBLESHOOTING ................7-15 LIGHTING SYSTEM ..................7-17 CIRCUIT DIAGRAM ................
Page 390 ELECTRICAL COMPONENTS..............7-67 CHECKING THE SWITCHES ..............7-71 CHECKING THE BULBS AND BULB SOCKETS ........7-74 CHECKING THE FUSES ................7-75 CHECKING AND CHARGING THE BATTERY........7-76 CHECKING THE RELAYS ..............7-79 CHECKING THE TURN SIGNAL RELAY ..........7-80 CHECKING THE DIODES............... 7-81 CHECKING THE IGNITION SPARK GAP..........
Page 392: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 393 IGNITION SYSTEM 3. Main switch 4. Main fuse 6. Battery 11.Relay unit 14.Neutral switch 16.Sidestand switch 19.Crankshaft position sensor 23.Lean angle sensor 27.ECU (electronic control unit) 28.Cylinder-#1 left ignition coil 29.Cylinder-#1 right ignition coil 30.Cylinder-#2 left ignition coil 31.Cylinder-#2 right ignition coil 32.Spark plug 68.Engine stop switch 77.Ignition fuse...
Page 394: Engine Stopping Due To Sidestand Operation
IGNITION SYSTEM ET1D71043 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 395: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rider seat bracket assembly 4. Fuel tank 5. Air filter case 6.
Page 396 IGNITION SYSTEM NG → 7. Check the crankshaft position sen- sor. Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor. SHAFT POSITION SENSOR” on page 7-84. OK ↓ NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch.
Page 397 IGNITION SYSTEM...
Page 398: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 399 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 6. Battery 8. Starter relay 9. Starter motor 10.Diode 1 (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 11.Relay unit 12.Starting circuit cut-off relay 14.Neutral switch 15.Diode 2 (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 16.Sidestand switch 27.ECU (electronic control unit) 54.Clutch switch 68.Engine stop switch...
Page 400: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 401 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
Page 402: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Headlight assembly NG → 1. Check the fuses. (Main, ignition and ECU (for XV19S(C)/ XV19M(C)/ Replace the fuse(s).
Page 403 ELECTRIC STARTING SYSTEM NG → 8. Check the diode 2. (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) Replace the diode 2. Refer to “CHECKING THE DI- ODES” on page 7-81. OK ↓ NG → 9. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay.
Page 404: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-13...
Page 405 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 6. Battery 7-14...
Page 406: Troubleshooting
CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Rectifier/regulator cover 3. Lead cover NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 407 CHARGING SYSTEM 7-16...
Page 408: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-17...
Page 409 LIGHTING SYSTEM 3. Main switch 4. Main fuse 6. Battery 27.ECU (electronic control unit) 44.Meter light 47.High beam indicator light 52.Headlight relay 55.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 64.Headlight (high beam) 65.Headlight (low beam) 70.Accessory light switch 71.Accessory light (OPTION) 72.Tail/brake light...
Page 410: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license light, position light, meter light or accessory light (OPTION). NOTE: • Before troubleshooting, remove the following part(s): 1.
Page 411 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 7-17. OK ↓ The lighting system circuit is OK. 7-20...
Page 412: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-21...
Page 413 SIGNALING SYSTEM 3. Main switch 4. Main fuse 5. Backup fuse (odometer and clock) 6. Battery 11.Relay unit 14.Neutral switch 18.Fuel sender (fuel pump) 24.Speed sensor 27.ECU (electronic control unit) 39.Neutral indicator light 40.Multi-function meter 43.Fuel level warning light 45.Left turn signal indicator light 46.Right turn signal indicator light 48.Fuel sender (fuel tank) 49.Horn 1...
Page 414: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel level gauge fails to operate. • The speedometer fails to operate. NOTE: •...
Page 415 SIGNALING SYSTEM NG → 2. Check the horns. Refer to “CHECKING THE Replace the horn(s). HORNS” on page 7-86. OK ↓ NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring.
Page 416 SIGNALING SYSTEM NG → 4. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-21. OK ↓ This circuit is OK. The neutral indicator light fails to come on. NG →...
Page 417 SIGNALING SYSTEM NG → 2. Check the fuel sender (fuel pump). Refer to “CHECKING THE FUEL Replace the fuel pump assembly. SENDER (FUEL PUMP)” on page 7-88. OK ↓ NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”...
Page 418: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-27...
Page 419 FUEL INJECTION SYSTEM 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Diode 2 (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 16.Sidestand switch 17.Fuel pump 19.Crankshaft position sensor 20.Throttle position sensor 21.Cylinder-#1 intake air pressure sensor 22.Cylinder-#2 intake air pressure sensor...
Page 420: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 421: Self-Diagnostic Function Table
FUEL INJECTION SYSTEM EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
Page 422 FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Able Able (depending (depending Cylinder-#1 left or Malfunction detected in the prima- on the on the right ignition coil ry wire of the cylinder-#1 left or number of number of (faulty ignition)
Page 423: Troubleshooting Method
FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Engine has been left idling. (The ECU automatically stops the en- Engine idling stop Able Able gine after 20 minutes if it is left idling.) Communication error with the meter Able / un-...
Page 424: Diagnostic Mode
FUEL INJECTION SYSTEM 5. Erase the malfunction history in the diagnos- The engine operation is not normal but the tic mode. Refer to “Sensor operation table engine trouble warning light does not come (Diagnostic code No. 62)”. 1. Check the operation of following sensors and NOTE: actuators in the Diagnostic mode.
Page 425 FUEL INJECTION SYSTEM “d01 d70” “d70 d01” 7. Verify the operation of the sensor or actuator. • Sensor operation The data representing the operating conditions of the sensor appears on the odometer/trip meter/fu- el reserve trip meter/clock LCD. • Actuator operation Set the engine stop switch to “...
Page 426 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. A break or disconnection of • Open circuit in wire harness (ECU coupler). the blue/black lead of the • Malfunction in ECU. ECU is detected. • Open or short circuit in wire harness. Air temperature sensor: •...
Page 427 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire sub lead. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in cylinder-#2 left or right igni- primary wire of the cylin- tion coil.
Page 428 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. • Malfunction in meter. No signals are received Er-1 • Malfunction in ECU. — from the ECU. • Defective wire connection of the ECU cou- pler.
Page 429 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Fuel system voltage Approximately 12.0 Set the engine stop switch (battery voltage) to “ ”, and then compare with the actually measured battery voltage. (If the bat- tery voltage is lower, per- form recharging.) Engine temperature Displays the engine tempera-...
Page 430 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Control number 0–255 — Actuator operation table Diag- nostic Item Actuation Checking method code Actuates the cylinder-#1 left or right ignition coil five times Check the spark five times. Cylinder-#1 left or right ig- at one-second intervals.
Page 431: Troubleshooting Details
FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the headlight relay for five cycles of five sec- onds. (ON 2 seconds, OFF 3 Check the operating sound Headlight relay seconds) of the headlight relay five Illuminates the engine trou- times.
Page 432 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor.
Page 433 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 434 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#1 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Cylinder-#1 intake air pressure sensor •...
Page 435 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
Page 436 FUEL INJECTION SYSTEM Fault code No. Symptom EXUP servo motor circuit: open or short circuit detected. Diagnostic code No. EXUP servo motor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 437 FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/black lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Execute the diagnostic mode. If the transmis- •...
Page 438 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of O sensor. Check for looseness or pinching. Starting the en- gine and oper- Connections •...
Page 439 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 440 FUEL INJECTION SYSTEM Fault code No. Symptom Cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code No. Cylinder-#2 intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Cylinder-#2 intake air pressure sensor •...
Page 441 FUEL INJECTION SYSTEM Fault code No. Symptom Engine temperature sensor: open or short circuit detect- Diagnostic code No. Engine temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of engine temperature Check for looseness or pinching. Turning the sensor.
Page 442 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 443 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code No. 31, 33 Cylinder-#2 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 444 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 445 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code No. 31, 33 Cylinder-#2 left or right ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 446 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method ECU fuse is blown. (for XV19S(C)/ • Check the ECU fuse. (for ISC valve re- XV19M(C)/ XV19CTS(C)/ XV19S(C)/ XV19M(C)/...
Page 447 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 448 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 449 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 450 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method...
Page 451 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •...
Page 452 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 453 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
Page 454: Fuel Pump System
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-63...
Page 455 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 13.Fuel pump relay 15.Diode 2 (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 17.Fuel pump 27.ECU (electronic control unit) 68.Engine stop switch 77.Ignition fuse 81.ECU fuse (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 7-64...
Page 456 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rider seat bracket assembly 4. Left side cover 5. Headlight assembly NG → 1.
Page 457 FUEL PUMP SYSTEM NG → 8. Check the entire fuel pump system wiring. Properly connect or repair the fuel pump Refer to “CIRCUIT DIAGRAM” on system wiring. page 7-63. OK ↓ Replace the ECU. 7-66...
Page 458: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-67...
Page 459 ELECTRICAL COMPONENTS 1. Cylinder-#2 right ignition coil (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 2. Cylinder-#2 left ignition coil (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 3. Fuel sender 4. Engine temperature sensor 5. Cylinder-#1 left ignition coil (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) Cylinder-#2 right ignition coil (for XV19CS(C)/ XV19C(C)) 6.
Page 460 ELECTRICAL COMPONENTS 7-69...
Page 461 ELECTRICAL COMPONENTS 1. Air temperature sensor 2. Main switch 3. Cylinder-#2 intake air pressure sensor 4. Throttle position sensor 5. Cylinder-#1 intake air pressure sensor 6. Fuse box 7. Starter relay 8. Fuel injection system fuse 9. Battery 10. Diode 2 (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) 11.
Page 462: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES R Br L/Y L/B (GRAY) Ch Br/W Dg B Y/R (BLUE) R/W B/R R/W B/R G/Y G/B G/L L/B (GRAY) L/W W/B (GRAY) G/Y G/B (BLACK) PUSH Br/W L/B G/L (GRAY) Y G/L G L/Y B/Y (BLACK) (BLACK)
Page 463 ELECTRICAL COMPONENTS 1. Main switch 2. Engine stop switch 3. Start switch 4. Accessory light switch 5. Front brake light switch 6. Neutral switch 7. Sidestand switch 8. Rear brake light switch 9. Clutch switch 10. Horn switch 11. Dimmer switch 12.
Page 464 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 465 ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB • Bulb SOCKETS EW1D71009 NOTE: WARNING Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continuity down.
Page 466 ELECTRICAL COMPONENTS NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL Checking the condition of the bulb sockets 3.
Page 467 ELECTRICAL COMPONENTS For XV19CS(C)/ XV19C(C) • DO NOT SMOKE when charging or han- dling batteries. Amperage • KEEP BATTERIES AND ELECTROLYTE Fuses Q’ty rating OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it Main 50 A can cause severe burns or permanent eye Ignition 25 A...
Page 468 ELECTRICAL COMPONENTS NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive battery ter- minal is disconnected). • No charging is necessary when the open-cir- cuit voltage equals or exceeds 12.8 V. b.
Page 469 ELECTRICAL COMPONENTS EWA13300 WARNING Do not quick charge a battery. ECA13670 CAUTION: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat- tery overheating and battery plate damage.
Page 470 ELECTRICAL COMPONENTS f. If charging requires more than 5 hours, it is ECA13630 CAUTION: advisable to check the charging current after First, connect the positive battery lead “1”, a lapse of 5 hours. If there is any change in and then the negative battery lead “2”. the amperage, readjust the voltage to obtain the standard charging current.
Page 471 ELECTRICAL COMPONENTS Starter relay 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3” and “4”) Headlight relay 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe 4. Negative tester probe Result Continuity (between “3”...
Page 472 ELECTRICAL COMPONENTS EAS28050 CHECKING THE DIODES Relay unit (diode) 1. Check: • Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. Turn the main switch to “ON”. c. Measure the turn signal relay input voltage. NOTE: L LLL L LLL...
Page 473 ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Continuity d. Check the relay unit (diode) for no continuity. Positive tester probe → sky blue L LLL L LLL L LLL L LLL L LLL “1” Negative tester probe → Diode 1 (for XV19S(C)/ XV19M(C)/ black/yellow “2”...
Page 474 ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM Pocket tester a. Disconnect the spark plug cap from the spark 90890-03112 plug. Analog pocket tester b. Connect the ignition checker “1” as shown. YU-03112-C Ignition checker 90890-06754 NOTE: Opama pet-4000 spark checker The pocket tester and the analog pocket tester...
Page 475 ELECTRICAL COMPONENTS Secondary coil resistance 8.64–12.96 kΩ M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the igni- tion coil. b. Connect the pocket tester (Ω × 1k) to the ig- nition coil as shown. Pocket tester 90890-03112 c.
Page 476 ELECTRICAL COMPONENTS • Positive tester probe → gray “1” • Negative tester probe → black “2” c. Turn the lean angle sensor to 65°. d. Measure the lean angle sensor output volt- age. L LLL L LLL L LLL L LLL L LLL ET1D71013 b.
Page 477 ELECTRICAL COMPONENTS 2. Check: b. Connect the pocket tester (DC 20 V) to the • Stator coil resistance rectifier/regulator coupler as shown. Out of specification → Replace the stator coil. Pocket tester 90890-03112 Stator coil resistance 0.112–0.168 Ω Analog pocket tester YU-03112-C M MMM M MMM...
Page 478 ELECTRICAL COMPONENTS A. Horn 1 A. Horn 1 B. Horn 2 B. Horn 2 c. Measure the horn resistance. L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL EAS28210 CHECKING THE ENGINE TEMPERATURE 2.
Page 479 ELECTRICAL COMPONENTS • Positive tester probe → green “1” • Negative tester probe → black “2” b. Move the fuel sender float to maximum “3”/minimum “4” level position. b. Immerse the engine temperature sensor “1” in a container filled with water “2”. NOTE: Make sure that the engine temperature sensor terminals do not get wet.
Page 480 ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → white “1” • Negative tester probe → black “2” b. Measure the fuel sender resistance. L LLL L LLL L LLL L LLL L LLL ET1D71044 CHECKING THE FUEL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis de-...
Page 481 ELECTRICAL COMPONENTS c. Connect the battery (DC 12 V) to the fuel • Positive tester probe → pump terminals as shown. blue “1” • Negative tester probe → • Positive battery lead → black “2” red/blue “2” • Negative battery lead → black “3”...
Page 482 ELECTRICAL COMPONENTS ECA14390 EW1D71004 CAUTION: WARNING To prevent damaging the EXUP servo motor, • Handle the air temperature sensor with perform this test within a few seconds of special care. connecting the battery. • Never subject the air temperature sensor to strong shocks.
Page 483: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ............... 8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ............ 8-1 POOR MEDIUM AND HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING................ 8-2 SHIFT PEDAL DOES NOT MOVE ............8-2 JUMPS OUT OF GEAR................8-2 FAULTY CLUTCH ..................8-2 OVERHEATING ..................8-3 POOR BRAKING PERFORMANCE............
Page 484 TROUBLESHOOTING • Sucked-in air EAS28450 TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery NOTE: • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •...
Page 485 TROUBLESHOOTING • Improper throttle cable free play • Foreign object between transmission gears • Flooded throttle body • Improperly assembled transmission EAS28550 Electrical system JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2.
Page 486 TROUBLESHOOTING • Deteriorated oil • Damaged damper rod assembly bolt copper washer EAS28590 • Cracked or damaged cap bolt O-ring OVERHEATING Malfunction Engine • Bent or damaged inner tube 1. Cylinder head(s) and piston(s) • Bent or damaged outer tube •...
Page 487 TROUBLESHOOTING • Faulty turn signal relay EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM • Burnt-out turn signal bulb Headlight does not come on Horn does not sound • Wrong headlight bulb • Improperly adjusted horn • Too many electrical accessories • Damaged or faulty horn •...
Page 488: Wiring Diagram
EAS28740 54. Clutch switch EAS28750 WIRING DIAGRAM COLOR CODE 55. Dimmer switch Black 56. Turn signal switch XV19SX(C)/XV19MX(C)/XV19CT Brown 57. Horn switch SX(C)/XV19CTMX(C) 2008 Chocolate 58. Select switch 1. AC magneto Dark green 59. Front right turn signal/position 2. Rectifier/regulator Green light 3.
Page 489 EAS1D77006 56. Front right turn signal/position EAS1D77011 WIRING DIAGRAM COLOR CODE light Black 57. Front left turn signal/position XV19CSX(C)/XV19CX(C) 2008 Brown light 1. AC magneto Chocolate 58. Headlight 2. Rectifier/regulator Dark green 59. Accessory light (OPTION) 3. Main switch Green 60.
Page 492 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 493 XV19SX(C)/XV19MX(C)/XV19CTSX(C)/XV19CTMX(C) 2008 WIRING DIAGRAM (BLUE) (BLUE) WIRE HARNESS SUB-WIRE-HARNESS2 (BLACK) (BLACK) WIRE HARNESS SUB-WIRE-HARNESS3 (BLACK) (GRAY) (BLACK) (BLACK) (BLACK) WIRE HARNESS SUB-WIRE-HARNESS4 (GRAY) (GRAY) (BLACK) (BLACK) (BLACK) (BLACK) (GRAY) WIRE HARNESS SUB-WIRE-HARNESS2 (DARK GRAY) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) PUSH (BLUE) (BLUE)
Page 494 XV19CSX(C)/XV19CX(C) 2008 WIRING DIAGRAM (BLACK) (BLACK) (BLACK) (BLUE) (BLUE) (GRAY) WIRE HARNESS SUB-WIRE-HARNESS1 (GRAY) WIRE HARNESS SUB-WIRE-HARNESS2 (GRAY) (RED) (RED) (DARK GRAY) (BLACK) (BLACK) (BLACK) WIRE HARNESS SUB-WIRE-HARNESS2 (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (GREEN) (GREEN) PUSH (BLACK) (BLACK) (BLACK) (YELLOW) (YELLOW) (GRAY)

This manual is also suitable for:

Xv19cx(c)Xv19mx(c)Xv19ctsx(c)Xv19ctmx(c)Xv19csx(c)

Yamaha XV19SX(C) Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Periodic Maintenance

Engine

Chassis

Electrical System

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly and Swingarm

Engine

Engine Removal

Camshafts

Cylinder Heads

Valves and Valve Springs

Cylinders and Pistons

Clutch

Shift Shaft

Generator and Starter Clutch

Electric Starter

Transfer Gear Case

Crankcase

Oil Pump

Crankshaft

Transmission

Fuel System

Fuel Tank

Throttle Bodies

Isc (Idle Speed Control) Unit

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha XV19SX(C)

Summary of Contents for Yamaha XV19SX(C)