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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.
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. •...
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.
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
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......
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.
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.
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.
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.
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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.
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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.
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”...
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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...
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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”...
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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.
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.
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.
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. •...
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.
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)/...
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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)
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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)
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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...
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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...
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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)
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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)
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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...
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.
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...
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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...
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LUBRICATION SYSTEM CHART AND DIAGRAMS 2-45...
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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...
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LUBRICATION SYSTEM CHART AND DIAGRAMS 2-47...
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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...
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LUBRICATION SYSTEM CHART AND DIAGRAMS 2-49...
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LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Transfer gear oil pump 2. Middle driven shaft 2-50...
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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.
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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.
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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.
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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.
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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.
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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.
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CABLE ROUTING (for XV19CS(C)/ XV19C(C)) E F F 2-71...
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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.
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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.
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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.
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 .............
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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 ........
√ √ 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...
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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.
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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.
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.
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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)
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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.
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.
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.
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.
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.
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.
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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...
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)
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.
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”...
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.
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.
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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”...
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 →...
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.
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.
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.
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...
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.
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. •...
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.
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”...
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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...
• 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):...
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...
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...
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.
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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...
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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..........
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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 ......
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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...
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 •...
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.
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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...
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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...
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.
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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.
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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 •...
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.
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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 •...
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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.
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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 •...
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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.
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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...
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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...
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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...
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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 •...
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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 •...
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 •...
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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 • •...
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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 •...
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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...
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...
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...
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.
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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.
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 •...
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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 •...
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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 •...
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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.
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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...
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.
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...
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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”...
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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...
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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.
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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...
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.
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 •...
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 •...
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...
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.
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.
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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.
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-...
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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 •...
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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 •...
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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...
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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...
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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.
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.
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.
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”...
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.
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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”...
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 •...
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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 •...
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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 •...
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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 •...
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.
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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...
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HANDLEBAR Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 4-65...
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 •...
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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 •...
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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 •...
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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...
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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.
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.
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.
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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”...
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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...
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 •...
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.
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 •...
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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 •...
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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 •...
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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 •...
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...
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 •...
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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 • •...
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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...
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 •...
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...
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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”...
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 •...
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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 •...
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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.
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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: •...
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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...
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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 ..........
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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..........
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 •...
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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 •...
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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 •...
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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 • •...
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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 • •...
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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 •...
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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 •...
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”...
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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 •...
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.
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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 • • • •...
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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 • • • •...
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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 •...
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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 •...
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 •...
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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.
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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 •...
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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...
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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 •...
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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 •...
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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...
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.
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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.
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 •...
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 →...
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–...
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.
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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.
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”.
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”...
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.
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.
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 •...
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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 •...
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.
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.
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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...
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 •...
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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.
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: •...
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.
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 •...
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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.
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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-...
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” •...
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.
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.
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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 ˚...
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.
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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-...
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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.
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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 •...
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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 •...
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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 •...
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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...
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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...
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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...
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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 •...
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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.
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.
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 •...
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.
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: •...
(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.
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.
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.
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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...
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...
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 •...
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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...
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...
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...
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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.
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”...
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 •...
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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 •...
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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...
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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 •...
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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 •...
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.
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.
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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. •...
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 •...
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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 •...
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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 •...
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. •...
• 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.
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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...
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.
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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...
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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.
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 •...
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...
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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.
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: •...
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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°...
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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...
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.
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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-...
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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.
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...
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.
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”...
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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.
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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..........
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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 •...
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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 •...
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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.
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.
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.
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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.
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.
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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”...
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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...
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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...
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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 •...
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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.
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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.
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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.
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.
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 •...
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...
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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 ................
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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..........
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.
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.
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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.
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: •...
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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.
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).
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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.
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”...
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.
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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...
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: •...
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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.
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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 →...
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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”...
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.
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.
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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)
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-...
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.
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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 “...
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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: •...
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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.
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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.
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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-...
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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.
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.
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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.
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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 •...
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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 •...
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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.
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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 •...
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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- •...
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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 •...
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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 •...
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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 •...
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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.
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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...
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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...
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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...
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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...
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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)/...
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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 •...
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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...
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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...
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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...
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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- •...
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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 •...
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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 •...
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-63...
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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...
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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.
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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...
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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.
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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.
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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.
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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...
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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.
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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.
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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.
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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...
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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”...
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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...
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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.
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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.
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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...
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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.
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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.
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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-...
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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”...
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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.
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............
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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- •...
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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.
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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 •...
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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 •...
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.
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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.
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