Assembling The Clutch Master Cylinder; Installing The Clutch Master Cylinder - Yamaha XV19SX(C) 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
5-71
EWA1D77010
WARNING
Proper clutch hose routing is essential to in-
sure safe vehicle operation. Refer to "CABLE
ROUTING (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C))" on page 2-51
and "CABLE ROUTING (for XV19CS(C)/
XV19C(C))" on page 2-67.
NOTE:
• Install the clutch hose at a right 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.
A
1
5–25˚
B
15–35˚
A. For XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C)
B. For XV19CS(C)/ XV19C(C)
3. Fill:
• Clutch master cylinder reservoir
(with the specified amount of the recom-
mended clutch fluid)
Recommended clutch fluid
Brake fluid DOT 4
CLUTCH
2