Assembling The Clutch Master Cylinder; Installing The Clutch Master Cylinder - Yamaha XV19SW Service Manual

• Clutch master cylinder reservoir diaphragm
Damage/wear → Replace.
4. Check:
• Clutch hose
Cracks/damage/wear → Replace.
EAS25300
ASSEMBLING THE CLUTCH MASTER
CYLINDER
EW1D71010
WARNING
• Before installation, all internal clutch com-
ponents must be cleaned and lubricated
with clean or new clutch fluid.
• Never use solvents on internal clutch com-
ponents.
Recommended clutch fluid
Brake fluid DOT 4
EAS25310
INSTALLING THE CLUTCH MASTER
CYLINDER
1. Install:
• Clutch master cylinder "1"
• Clutch master cylinder holder "2"
Clutch master cylinder holder
bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
NOTE:
• Align the end of the clutch lever holder with the
punch mark "a" on the handlebar.
• First, tighten the rear bolt, then the front bolt.
2
2. Install:
• Copper washers New
• Clutch hose "1"
• Clutch hose union bolt "2"
Clutch hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
1
a
5-67
EW1D71002
WARNING
Proper clutch hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING" on page 2-45.
NOTE:
• Install the clutch hose at 5–25° "a" angle to the
clutch master cylinder as shown in the illustra-
tion.
• While holding the clutch hose, tighten the
union bolt.
• Turn the handlebar to the left and right to make
sure the clutch hose does not touch other parts
(e.g., wire harness, cables, leads). Correct if
necessary.
1
a
3. Fill:
• Clutch master cylinder reservoir
(with the specified amount of the recom-
mended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
EWA13370
WARNING
• Use only the designated clutch fluid. Other
clutch fluids may cause the rubber seals to
deteriorate, causing leakage and poor
clutch performance.
• 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. 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. Therefore, always clean up any
spilt clutch fluid immediately.
CLUTCH
2