Yamaha XV19SW 2006 Service Manual
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Yamaha XV19SW 2006 Service Manual

Yamaha XV19SW 2006 Service Manual

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XV19SW(C)
XV19W(C)
XV19MW(C)
XV19CTSW(C)
XV19CTW(C)
XV19CTMW(C)
SERVICE MANUAL
LIT-11616-20-40
1D7-28197-11

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Summary of Contents for Yamaha XV19SW 2006

  • Page 1 XV19SW(C) XV19W(C) XV19MW(C) XV19CTSW(C) XV19CTW(C) XV19CTMW(C) SERVICE MANUAL LIT-11616-20-40 1D7-28197-11...
  • Page 2 EAS20050 XV19SW(C)/XV19W(C)/XV19MW(C)/ XV19CTSW(C)/XV19CTW(C)/XV19CTMW(C) SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, July 2006 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-11616-20-40...
  • 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 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 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..............1-4 IMPORTANT INFORMATION ................. 1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-8 REPLACEMENT PARTS ................

  • 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

    FEATURES ET1D71036 INSTRUMENT FUNCTIONS Multi-function meter unit EW1D71008 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. Speedometer 2. Fuel gauge 1. “SELECT” switch 3. Odometer/tripmeter/fuel reserve 2. “RESET” switch tripmeter/clock 4.
  • Page 14 FEATURES • The fuel gauge does not indicate the correct Tachometer 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 FEATURES 1. Speedometer needle 2. Tachometer needle 3. Fuel gauge needle 4. Item number 5. Brightness level 7. Push the “SELECT” switch. The odometer/tripmeter/clock display will re- turn to the prior mode.

  • Page 17: 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...

  • Page 18: 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 19: 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 20: 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 21 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 3-24 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-26, 4-71 90890-01403 Spanner wrench YU-33975 Damper rod holder...
  • Page 22 Piston pin puller set 5-46 90890-01304 Piston pin puller YU-01304 YU-01304 Universal clutch holder 5-60, 5-65 90890-04086 YM-91042 Sheave holder 5-60, 5-64, 90890-01701 5-74, 5-75 Primary clutch holder YS-01880-A Yamaha bond No. 1215 5-66, 5-76, 90890-85505 5-93 ® (Three Bond No.1215 1-13...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor puller 5-74 90890-01080 Stator rotor puller YM-01080-A Vacuum/pressure pump gauge set 6-12 90890-06756 Pressure gauge 6-12 90890-03153 Fuel pressure adapter 6-12 90890-03176 YM-03176 Digital circuit tester 6-12 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 7-83...
  • Page 24 SPECIAL TOOLS 1-15...

  • Page 25: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................ 2-10 ELECTRICAL SPECIFICATIONS..............2-13 TIGHTENING TORQUES................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-27 ENGINE ....................2-27 CHASSIS ....................

  • Page 26: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XV19SW 1D74 (USA) XV19SW 1D76 (CDN) XV19SWC 1D75 (California) XV19W 4D45 (USA) XV19W 4D47 (CDN) XV19WC 4D46 (California) XV19MW 4D54 (USA) XV19MW 4D56 (CDN) XV19MWC 4D55 (California) XV19CTSW 2C54 (USA) XV19CTSW 2C56 (CDN) XV19CTSWC 2C55 (California) XV19CTW 4P04 (USA) XV19CTW 4P06 (CDN)

  • Page 27: 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 17.0 L (4.49 US gal) (3.74 Imp.gal)
  • Page 28 ENGINE SPECIFICATIONS Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in) Limit 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing clearance 0.10–0.15 mm (0.0039–0.0059 in) Limit 0.22 mm (0.0087 in) Oil-pump-housing-to-inner-and-outer-rotor clearance 0.04–0.09 mm (0.0016–0.0035 in) Limit 0.160 mm (0.0063 in) Spark plug (s) Manufacturer/model NGK/DPR8EA-9 Manufacturer/model...
  • Page 29 ENGINE SPECIFICATIONS 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) Intake 0.00–0.04 mm (0.0000–0.0016 in)
  • Page 30 ENGINE SPECIFICATIONS Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) 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...
  • Page 31 ENGINE SPECIFICATIONS Valve push rod runout 0.3 mm (0.012 in) 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...
  • Page 32 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 33 ENGINE SPECIFICATIONS Primary reduction system Spur gear Primary reduction ratio 72/51 (1.412) Secondary reduction system Belt drive Secondary reduction ratio 70/31 (2.258) 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 34 ENGINE SPECIFICATIONS Idling condition Engine idling speed 850–950 r/min Intake vacuum 31.3–35.3 kPa (9.3–10.4 inHg) (235–265 mmHg) Oil temperature 80.0–90.0 °C (176.00–194.00 °F) Throttle cable free play 4.0–6.0 mm (0.16–0.24 in)

  • Page 35: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 31.20 ° Trail 152.0 mm (5.98 in) Front wheel Wheel type Cast wheel 18M/C × MT4.00 Rim size Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 36 CHASSIS SPECIFICATIONS Front brake Type Dual disc brake Operation Right hand operation Front disc brake Disc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in) Brake disc thickness limit 4.5 mm (0.18 in) Brake disc deflection limit 0.10 mm (0.0039 in) Brake pad lining thickness (inner) 5.5 mm (0.22 in)
  • Page 37 CHASSIS SPECIFICATIONS Recommended oil Fork oil 10WT Quantity 571.0 cm³ (19.31 US oz) (20.10 Imp.oz) Level 124.0 mm (4.88 in) Rear suspension Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 180.0 mm (7.09 in) Limit...

  • Page 38: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Electrical Ignition timing (B.T.D.C.) 10.0 °/900 r/min Engine control unit Model/manufacturer F008T83271/MITSUBISHI Ignition coil Model/manufacturer 2JN/MORIC Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 39 Built-in, self-canceling device Turn signal blinking frequency 75.0–95.0 cycles/min 21(23) W × 2 + LED × 2 Wattage Fuel gauge Model/manufacturer 1D7/YAMAHA 9–11 Ω Sender unit resistance (full) 213–219 Ω Sender unit resistance (empty) Starting circuit cut-off relay Model/manufacturer G8R-30Y-V3/OMRON 162–198 Ω...
  • Page 40 ELECTRICAL SPECIFICATIONS Fuel pump relay Model/manufacturer G8R-30Y-V3/OMRON 162–198 Ω Coil resistance Thermo unit Model/manufacturer 5PX/DENSO 898.4–1098.0 Ω Resistance at 100°C Fuses Main fuse 50.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 25.0 A Auxiliary DC connector fuse 3.0 A...

  • Page 41: 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 42: 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 43 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pipe 2 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 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)
  • Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size 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 damper cover bolt 5 Nm (0.5 m·kg, 3.6 ft·lb) Engine oil filler plug 10 Nm (1.0 m·kg, 7.2 ft·lb) Camshaft sprocket cover plate 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Dipstick joint bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive pulley case bolt 70 Nm (7.0 m·kg, 50 ft·lb) Oil strainer bolt (oil tank) 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil pipe 5 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Transfer gear case cover plate 5 Nm (0.5 m·kg, 3.6 ft·lb)
  • Page 46 TIGHTENING TORQUES Cylinder head tightening sequence: A. Front cylinder B. Rear cylinder 2-21...

  • Page 47: 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) Engine mounting nut (rear upper 98 Nm (9.8 m·kg, 71 ft·lb) side) Engine mounting spacer bolt...
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Relay arm nut (relay arm and 59 Nm (5.9 m·kg, 43 ft·lb) connecting arm) Rear shock absorber assembly 40 Nm (4.0 m·kg, 29 ft·lb) nut (rear side) Rear shock absorber assembly 59 Nm (5.9 m·kg, 43 ft·lb) nut (front side) Upper drive belt cover bolt...
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Fuel tank bracket bolt (front side) 16 Nm (1.6 m·kg, 11 ft·lb) Fuel tank bracket nut (rear side) 10 Nm (1.0 m·kg, 7.2 ft·lb) Sub-fuel tank bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rider seat bracket bolt 23 Nm (2.3 m·kg, 17 ft·lb) Fuel tank and fuel tank bracket...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear fender bracket and frame 40 Nm (4.0 m·kg, 29 ft·lb) bolt Rear fender bracket and rear 23 Nm (2.3 m·kg, 17 ft·lb) fender bolt Passenger seat bolt 16 Nm (1.6 m·kg, 11 ft·lb) Rider seat bracket assembly and 7 Nm (0.7 m·kg, 5.1 ft·lb) seat lock assembly bolt...
  • Page 51 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drive pulley cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rectifier/regulator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Lead cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Rectifier/regulator bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive pulley cover plate bolt 5 Nm (0.5 m·kg, 3.6 ft·lb) Wire harness guide bolt...

  • Page 52: 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 53 Transmission gears (wheel and pinion) and collar Drive pulley nut and washer Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal Shift fork pawl Yamaha bond No.1215 (Three Bond Crankcase mating surface ® No.1215 Yamaha bond No.1215 (Three Bond...

  • Page 54: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing dust cover lip Lower bearing dust seal lip 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 Brake lever pivoting point and metal-to-metal moving parts...
  • Page 55 LUBRICATION POINTS AND LUBRICANT TYPES 2-30...

  • Page 56: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-31...
  • Page 57 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 58: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-33...
  • Page 59 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 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 61 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) 2-36...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
  • Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pipe 1 2. Oil pump 3. Oil strainer (crankcase) 4. Joint pipe 2-38...
  • Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-39...
  • Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil strainer (crankcase) 4. Oil pump A. To the oil filter cartridge 2-40...
  • Page 66 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-41...
  • Page 67 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 2-42...
  • Page 68 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-43...
  • Page 69 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Transfer gear oil pump 2. Middle driven shaft 2-44...

  • Page 70: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-45...
  • Page 71 CABLE ROUTING 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. Horn 1 10. Rear brake light switch 11.
  • Page 72 CABLE ROUTING 2-47...
  • Page 73 CABLE ROUTING 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 74 CABLE ROUTING 2-49...
  • Page 75 CABLE ROUTING 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 76 CABLE ROUTING 2 3 4 15 16 2-51...
  • Page 77 CABLE ROUTING 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. Throttle cable (accelerator cable) excess end of the tie.
  • Page 78 CABLE ROUTING 2-53...
  • Page 79 CABLE ROUTING 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 80 CABLE ROUTING 2-55...
  • Page 81 CABLE ROUTING 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. Fuel tank S. Install the air vent hose (fuel hose joint to fuel tank) 4.
  • Page 82 CABLE ROUTING 2-57...
  • Page 83 CABLE ROUTING 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 84 CABLE ROUTING 9 10 2-59...
  • Page 85 CABLE ROUTING 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. Rollover valve 2 8.
  • Page 86 CABLE ROUTING 2-61...

  • Page 87: 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 88 ELECTRICAL SYSTEM ................3-31 CHECKING AND CHARGING THE BATTERY........3-31 CHECKING THE FUSES ................ 3-31 REPLACING THE HEADLIGHT BULBS ..........3-31 ADJUSTING THE HEADLIGHT BEAMS..........3-32...

  • Page 90: Periodic Maintenance

    √ √ damage. tem (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32183 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 8000 mi...
  • Page 91 Lights, signals • Check operation. √ √ √ √ √ √ 26 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
  • Page 92 PERIODIC MAINTENANCE NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU38440 NOTE: • Air filter • This model’s air filter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it.

  • Page 93: 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 94 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 95 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 96: Synchronizing The Throttle Bodies

    ENGINE • Cylinder-#1 ignition coil cover Refer to “ENGINE REMOVAL” on page 5-1. • 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”...

  • Page 97: 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 98: Checking The Spark Plugs

    ENGINE 4. Check: M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut “1”. • Spark plug type b. Turn the adjusting nut “2” in direction “a” or “b” Incorrect → Change. until the specified throttle cable free play is obtained.

  • Page 99: Checking The Ignition Timing

    ENGINE 10.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. EAS20700 CHECKING THE IGNITION TIMING 5.

  • Page 100: 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 101 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 102: Checking The Transfer Gear Oil Level

    ENGINE EC1D71008 CAUTION: Oil gallery bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) When starting the engine make sure the dip- stick is securely fitted into the oil tank. L LLL L LLL L LLL L LLL L LLL 12.Fill: (when engine is disassembled) •...

  • Page 103: Changing The Transfer Gear Oil

    ENGINE 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 Refer to “ENGINE REMOVAL” on page 5-1. 2. Place a container under the transfer gear oil 8.

  • Page 104: Bleeding The Hydraulic Clutch System

    ENGINE • Refill with the same type of clutch fluid that is already in the system. Mixing clutch flu- ids may result in a harmful chemical reac- tion, leading to poor clutch performance. • When refilling, be careful that water does not enter the clutch fluid reservoir.

  • Page 105: 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 106: 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 3.

  • Page 107: Checking The Canister (For California Only)

    ENGINE • Muffler “3” EAS21090 CHECKING THE CANISTER (for California • Muffler bracket “4” only) Cracks/damage → Replace. 1. Remove: • Gaskets “5” • Horn 1 Exhaust gas leaks → Replace. Refer to “THROTTLE BODIES” on page 6-6. 2. Check: 2.
  • Page 108 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 109: Chassis

    CHASSIS EAS21140 CHASSIS EAS21190 ADJUSTING THE REAR DISC BRAKE 1. Check: • Brake pedal position (distance “a” from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position c. Tighten the locknut. 110.0 mm (4.33 in) EW1D71005 WARNING...

  • Page 110: Checking The Front Brake Pads

    CHASSIS EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • Front brake pad Wear indicator grooves “1” almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE”...

  • Page 111: Checking The Rear Brake Hoses

    CHASSIS EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1.

  • Page 112: Adjusting The Shift Pedal

    CHASSIS NOTE: NOTE: • Be careful not to spill any brake fluid or allow Loosening the bleed screw will release the pres- the brake master cylinder reservoir or brake sure and cause the brake lever to contact the fluid reservoir to overflow. throttle grip or the brake pedal to fully extend.

  • Page 113: Adjusting The Drive Belt Slack

    CHASSIS 1. Stand the vehicle on a level surface. M MMM M MMM M MMM M MMM M MMM a. Loosen both locknuts “1”. EWA13120 WARNING b. Turn the shift rod “2” in direction “a” or “b” until the specified installed shift rod length is ob- Securely support the vehicle so that there is tained.

  • Page 114: Checking And Adjusting The Steering Head

    CHASSIS NOTE: Using the alignment marks on each side of the swingarm, make sure that both belt pullers are in the same position for proper wheel alignment. d. Tighten the locknuts to specification. Locknut (drive belt adjusting bolt) 16 Nm (1.6 m·kg, 11 ft·lb) 3.

  • Page 115: Checking The Front Fork

    CHASSIS 3. Remove: Lower ring nut (final tightening • Upper bracket torque) Refer to “FRONT FORK” on page 4-60. 18 Nm (1.8 m·kg, 13 ft·lb) 4. Adjust: • Steering head d. Check the steering head for looseness or M MMM M MMM M MMM M MMM...

  • Page 116: Adjusting The Rear Shock Absorber Assembly

    CHASSIS 3. Hold the vehicle upright and apply the front Spring preload adjusting posi- brake. tions 4. Check: Installed spring length • Front fork operation Minimum Push down hard on the handlebar several 162.0 mm (6.38 in) times and check if the front fork rebounds Standard smoothly.
  • Page 117 CHASSIS EWA13190 WARNING It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: • Tire surfaces Damage/wear → Replace the tire. Wear limit (front) 1.0 mm (0.04 in) EWA13180 WARNING Wear limit (rear)

  • Page 118: Checking The Wheels

    WARNING cerning handling characteristics can be giv- en if a tire combination other than one Never attempt to make any repairs to the approved by Yamaha is used on this vehicle. wheel. NOTE: Front tire After a tire or wheel has been changed or re- Size placed, always balance the wheel.

  • Page 119: 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 Lithium-soap-based grease EAS21710...

  • Page 120: Electrical System

    ELECTRICAL SYSTEM 5. Replace: EAS21750 ELECTRICAL SYSTEM • Low beam headlight bulb M MMM M MMM M MMM M MMM M MMM a. Disconnect: EAS21760 CHECKING AND CHARGING THE BATTERY • Headlight coupler “1” Refer to “ELECTRICAL COMPONENTS” on b. Remove: page 7-67.
  • Page 121 ELECTRICAL SYSTEM 7. Install: • Headlight assembly 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: b. Disconnect: • Windshield (For XV19CTS(C)/ • Headlight coupler “1” XV19CT(C)/XV19CTM(C)) c.
  • Page 122 ELECTRICAL SYSTEM L LLL L LLL L LLL L LLL L LLL 3-33...
  • Page 123 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 ....................
  • Page 124 REAR BRAKE....................4-43 INTRODUCTION..................4-49 CHECKING THE REAR BRAKE DISC ........... 4-49 REPLACING THE REAR BRAKE PADS ..........4-49 REMOVING THE REAR BRAKE CALIPER ..........4-50 DISASSEMBLING THE REAR BRAKE CALIPER ........4-50 CHECKING THE REAR BRAKE CALIPER..........4-51 ASSEMBLING THE REAR BRAKE CALIPER ........4-51 INSTALLING THE REAR BRAKE CALIPER...........

  • Page 126: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield (For XV19CTS(C)/XV19CT(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 127: 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 128 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 129 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 130: 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 131 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 132 GENERAL CHASSIS Removing the sidebag brackets (For XV19CTS(C)/XV19CT(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 133: 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 134 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 135 GENERAL CHASSIS Removing the headlight 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. Air temperature sensor Headlight (low beam) coupler Disconnect.
  • Page 136 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 137 GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Headlight relay Turn signal relay Plastic locking tie Battery box For installation, reverse the removal proce- dure. 4-12...
  • Page 138 GENERAL CHASSIS Removing the air filter case 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 Refer to “GENERAL CHASSIS”...
  • Page 139 GENERAL CHASSIS Removing the air filter case 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 Air filter case bracket Air filter case joint clamp screw Loosen.

  • Page 140: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 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 • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 141 FRONT WHEEL Removing the front wheel and brake discs 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 • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 142 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. 4-17...

  • Page 143: 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: • Oil seals EWA13120 WARNING • Wheel bearings Securely support the vehicle so that there is M MMM M MMM M MMM M MMM...

  • Page 144: 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 145: Installing The Front Wheel (Front Brake Discs)

    FRONT WHEEL c. If the heavy spot does not stay in that posi- c. Turn the front wheel 90 ° so that the “X ” mark tion, install a heavier weight. is positioned as shown. d. Repeat steps (b) and (c) until the front wheel d.

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