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Yamaha XV19SW 2006 Service Manual Download Page 2

EAS20050

XV19SW(C)/XV19W(C)/XV19MW(C)/

XV19CTSW(C)/XV19CTW(C)/XV19CTMW(C)

SERVICE MANUAL

©2006 by Yamaha Motor Corporation, U.S.A.

First edition, July 2006

All rights reserved.

Any reproduction or unauthorized use 

without the written permission of 

Yamaha Motor Corporation, U.S.A. 

is expressly prohibited.

Printed in U.S.A.

P/N LIT-11616-20-40

Summary of Contents for XV19SW 2006

Page 1: ...SERVICE MANUAL XV19SW C XV19W C XV19MW C XV19CTSW C XV19CTW C XV19CTMW C LIT 11616 20 40 1D7 28197 11...

Page 2: ...C SERVICE MANUAL 2006 by Yamaha Motor Corporation U S A First edition July 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S...

Page 3: ...ded to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of it...

Page 4: ...ge 1 Sub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly s...

Page 5: ...14 15 16 LT New T R 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oi...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 FUEL SYSTEM 6 ELECTRICAL SYSTEM 7 TROUBLESHOOTING 8...

Page 8: ......

Page 9: ...F THE FI SYSTEM 1 2 FI SYSTEM 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 8 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PL...

Page 10: ...E 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...

Page 11: ...becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in plac...

Page 12: ...ming are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor air temperature sensor engine temperature sensor speed sen...

Page 13: ...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 and RESET switches except for setting the brightness control mode...

Page 14: ...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 Push the SELECT switch to switch the display between the odomete...

Page 15: ...d as soon as possible in order to avoid engine damage Brightness control mode The brightness can be adjusted for the following the multi function meter unit panel item num ber 1 the LCD item number 2...

Page 16: ...RES 1 7 7 Push the SELECT switch The odometer tripmeter clock display will re turn to the prior mode 1 Speedometer needle 2 Tachometer needle 3 Fuel gauge needle 4 Item number 5 Brightness level 4 2 3...

Page 17: ...correct installation of all parts 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...

Page 18: ...ase Oil bearings liberally when installing if appropri ate CAUTION ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassemb...

Page 19: ...l times 3 Check All connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect Lead Coupler Connector NOTE Make sure all connections are tight 5...

Page 20: ...t provided below to avoid any mistakes NOTE For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference page...

Page 21: ...rench 90890 01403 Spanner wrench YU 33975 3 26 4 71 Damper rod holder 90890 01460 4 64 4 66 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 64 4 66 Fork seal driver 90890 01442 Adjustabl...

Page 22: ...de reamer 6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 40 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 46 Universal clutch holder 90890 04086 YM 91042 5 60 5 65 Sheave holder 9...

Page 23: ...set 90890 06756 6 12 Pressure gauge 90890 03153 6 12 Fuel pressure adapter 90890 03176 YM 03176 6 12 Digital circuit tester 90890 03174 Model 88 Multimeter with tachometer YU A1927 6 12 Ignition chec...

Page 24: ...SPECIAL TOOLS 1 15...

Page 25: ...13 TIGHTENING TORQUES 2 16 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 16 ENGINE TIGHTENING TORQUES 2 17 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 27 ENGINE 2 27 CHASSIS...

Page 26: ...19CTMW 4P14 USA XV19CTMW 4P16 CDN XV19CTMWC 4P15 California Dimensions Overall length 2580 mm 101 6 in Overall width 1100 mm 43 3 in Overall height XV19S C XV19 C XV19M C 1100 mm 43 3 in XV19CTS C XV1...

Page 27: ...oil filter cartridge replacement 4 10 L 4 33 US qt 3 61 Imp qt With oil filter cartridge replacement 4 90 L 5 18 US qt 4 31 Imp qt Oil pressure hot 60 0 kPa 900 r min 8 7 psi 900 r min 0 60 kgf cm 90...

Page 28: ...5 000 25 021 mm 0 9843 0 9851 in Camshaft journal diameter crankcase side 24 957 24 980 mm 0 9826 0 9835 in Camshaft to crankcase clearance 0 020 0 064 mm 0 0008 0 0025 in Camshaft cover hole inside d...

Page 29: ...0 36 10 mm 1 4134 1 4213 in Valve head diameter A exhaust 30 90 31 10 mm 1 2165 1 2244 in 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...

Page 30: ...K1 exhaust 16 58 N mm 94 67 lb in 1 69 kgf mm Spring rate K2 exhaust 21 98 N mm 125 51 lb in 2 24 kgf mm Installed compression spring force intake 217 00 249 00 N 48 78 55 98 lb 22 13 25 39 kgf Instal...

Page 31: ...0 9073 in Piston pin outside diameter 22 991 23 000 mm 0 9052 0 9055 in Limit 22 971 mm 0 9044 in Piston pin to piston pin bore clearance 0 004 0 024 mm 0 00016 0 00094 in Limit 0 074 mm 0 00291 in Pi...

Page 32: ...0012 0 0024 in Limit 0 10 mm 0 0039 in Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push Operation Left hand operation Friction plate 1 3 thickness 2 90 3 10 mm 0 114 0 1...

Page 33: ...Air filter element Oil coated paper element Fuel pump Pump type Electrical Model manufacturer 1D7 MITSUBISHI Maximum consumption amperage 5 5 A Output pressure 441 0 637 0 kPa 63 9 92 4 psi 4 41 6 37...

Page 34: ...FICATIONS 2 9 Idling condition Engine idling speed 850 950 r min Intake vacuum 31 3 35 3 kPa 9 3 10 4 inHg 235 265 mmHg Oil temperature 80 0 90 0 C 176 00 194 00 F Throttle cable free play 4 0 6 0 mm...

Page 35: ...in Front tire Type Tubeless Size 130 70R18M C 63H Manufacturer model DUNLOP D251F Manufacturer model BRIDGESTONE G851 RADIAL G Wear limit front 1 0 mm 0 04 in Rear tire Type Tubeless Size 190 60R17M C...

Page 36: ...mm 0 22 in Brake disc deflection limit 0 15 mm 0 0059 in Brake pad lining thickness inner 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Brake pad lining thickness outer 5 8 mm 0 23 in Limit 0 8 mm 0 03 in Maste...

Page 37: ...6 50 N mm 1007 82 lb in 18 00 kgf mm Spring stroke K1 0 0 50 0 mm 0 00 1 97 in Optional spring available No Enclosed gas air pressure STD 0 98 MPa 139 4 psi 9 8 kgf cm Spring preload adjusting positio...

Page 38: ...to Model manufacturer F4T38971 MITSUBISHI Standard output 14 0 V 32 0 A 5000 r min Stator coil resistance 0 112 0 168 Rectifier regulator Regulator type Semi conductor short circuit Model manufacturer...

Page 39: ...08 in Mica undercut depth 1 50 mm 0 06 in Starter relay Model manufacturer 2768079 A JIDECO Amperage 180 0 A Coil resistance 4 18 4 62 Horn Horn type Eddy Quantity 2 pcs Model manufacturer YP 12 NIKKO...

Page 40: ...sistance at 100 C 898 4 1098 0 Fuses Main fuse 50 0 A Headlight fuse 20 0 A Taillight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 25 0 A Auxiliary DC connector fuse 3 0 A ECU fuse 10 0 A Fu...

Page 41: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque speci...

Page 42: ...7 2 ft lb Left balancer weight bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Left balancer idle gear shaft bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Camshaft driven gear bolt M10 1 60 Nm 6 0 m kg 43 ft lb Camshaft driv...

Page 43: ...Locknut EXUP cable M6 2 7 Nm 0 7 m kg 5 1 ft lb EXUP valve pulley cover bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Rear exhaust pipe joint cover bolt M6 3 10 Nm 1 0 m kg 7 2 ft lb Muffler and muffler bracket b...

Page 44: ...rter motor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Primary drive gear bolt M12 1 100 Nm 10 0 m kg 72 ft lb Clutch boss nut M20 1 105 Nm 10 5 m kg 75 ft lb Stake Clutch spring plate retainer bolt M6 6 8 Nm...

Page 45: ...Nm 1 0 m kg 7 2 ft lb Oil tank bracket bolt M8 2 28 Nm 2 8 m kg 20 ft lb Shift shaft spring stopper bolt M8 1 22 Nm 2 2 m kg 16 ft lb Stopper lever bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Crankshaft positi...

Page 46: ...TIGHTENING TORQUES 2 21 Cylinder head tightening sequence 3 1 2 4 A B 3 1 2 4 A Front cylinder B Rear cylinder...

Page 47: ...de M12 1 105 Nm 10 5 m kg 75 ft lb Engine bracket nut front upper side M10 4 53 Nm 5 3 m kg 38 ft lb Engine cross member bracket bolt M10 2 30 Nm 3 0 m kg 22 ft lb Engine bracket nut left rear low er...

Page 48: ...tening torque M30 1 18 Nm 1 8 m kg 13 ft lb See NOTE Hose guide and lower handlebar holder nut M10 2 32 Nm 3 2 m kg 23 ft lb Front brake master cylinder hold er bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Fron...

Page 49: ...8 2 16 Nm 1 6 m kg 11 ft lb Front brake caliper bolt M10 4 40 Nm 4 0 m kg 29 ft lb Front brake hose union bolt front brake caliper side M10 2 32 Nm 3 2 m kg 23 ft lb Rear brake caliper bolt M10 2 27 N...

Page 50: ...ster cylinder bolt M8 2 23 Nm 2 3 m kg 17 ft lb Rear brake master cylinder bracket and frame bolt M8 2 23 Nm 2 3 m kg 17 ft lb Rear brake master cylinder cover bolt M8 2 16 Nm 1 6 m kg 11 ft lb Brake...

Page 51: ...Rear shock absorber locknut M50 1 30 Nm 3 0 m kg 22 ft lb Windshield holder bracket as sembly bolt M8 4 30 Nm 3 0 m kg 22 ft lb Windshield holder nut M8 4 23 Nm 2 3 m kg 17 ft lb Windshield bracket b...

Page 52: ...driven gear housing Flange bolts left balancer drive gear and right balancer driven gear Camshaft cam lobes and camshaft journals Flange bolt camshaft gear Valve push rod end balls Valve stems intake...

Page 53: ...ve pulley nut and washer Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal Shift fork pawl Crankcase mating surface Yamaha bond No 1215 Three Bond No 1215 Stator co...

Page 54: ...moving parts Clutch lever pivoting point and metal to metal moving parts Brake pedal shaft pivoting point Shift pedal pivoting point Passenger footrest pivoting point and ball Sidestand pivoting point...

Page 55: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 30...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 22 21 19 18 20 23 17 16 15 11 10 14 13 9 8 12 14 7 6 5 4 2 3 1 9 8...

Page 57: ...8 Front cylinder head cover 9 Rear cylinder head cover 10 Rear cylinder camshaft 11 Front cylinder camshaft 12 Rear valve lifter case 13 Front valve lifter case 14 Push rod 15 Crankshaft 16 Camshaft...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 EAS20410 LUBRICATION DIAGRAMS E A A B B E E D D C C A A B E D D B 2 9 3 8 1 10 4 5 6 7 8 11 4 5...

Page 59: ...EM CHART AND DIAGRAMS 2 34 1 Oil tank 2 Dipstick 3 Oil pipe 2 4 Oil delivery pipe 1 5 Oil filter cartridge 6 Oil delivery pipe 2 7 Oil pipe 3 8 Oil pipe 4 9 Oil pipe 5 10 Oil strainer oil tank 11 Oil...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 35 D D B B D D C C A A B C C B 3 2 1 3 4 6 7 6 7 5...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 36 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Oil pipe 1 5 Crankshaft 6 Oil pipe F mark 7 Oil pipe R mark...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 A A A A 1 3 2 4...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 38 1 Oil pipe 1 2 Oil pump 3 Oil strainer crankcase 4 Joint pipe...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 A 1 2 3 4...

Page 65: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 40 1 Main axle 2 Drive axle 3 Oil strainer crankcase 4 Oil pump A To the oil filter cartridge...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 A A A 1 5 5 1 3 2 4 B B B B...

Page 67: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 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...

Page 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 1 2...

Page 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Transfer gear oil pump 2 Middle driven shaft...

Page 70: ...CABLE ROUTING 2 45 EAS20430 CABLE ROUTING C D F F C D B B C C D D F F A E A E B B 1 1 1 1 2 3 4 5 5 5 5 5 6 6 6 6 7 7 7 7 8 9 10 11 A B C E F G D...

Page 71: ...r switch leads Either lead can be routed on top B 70 mm 2 76 in C 5 25 D 10 30 E Fasten the rear brake light switch lead with the plastic locking tie Face the end of the plastic locking tie inward and...

Page 72: ...CABLE ROUTING 2 47 B B C D D E E B B G G F F E E D D A A C F F 1 1 1 1 2 2 2 2 2 3 3 4 4 5 6 6 7 8 8 9 12 G G 3 B G J H I A C D E F K L 10 11...

Page 73: ...the headlight leads front turn signal position light leads and accessory light lead with the holders along the side of the headlight housing E Place the headlight leads front turn signal position ligh...

Page 74: ...B B I F F A B C D E F G H I J K L M S 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 14 14 14 14 15 16 17 21 26 F F G G D D H H H H K I B B C C Z 3 3 20 23 24 25 S W V T T T AH 18 19 27 AE AD AF U AB AA AC 28 Y...

Page 75: ...ront brake hose H Make sure that the wire harness is not twisted between the fuel tank and the headlight assembly I Position the cylinder 2 left and right spark plug leads sub wire harness 2 coupler a...

Page 76: ...A A B B C C D D E G G F H H F A B C D E F G H I J K L M N N O Q R U S T O Q R S V Y Z 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 15 16 17 18 15 16 18 34 18 35 19 20 21 22 23 24 24 25 26 27 28 29 30 31...

Page 77: ...itch lead and sidestand switch lead to the inside of the frame boss N Fasten the starter motor lead horn 1 lead rear brake light switch lead and sidestand switch lead with the plastic locking tie Face...

Page 78: ...CABLE ROUTING 2 53...

Page 79: ...e upward and then cut off the excess end of the tie H Connect the ECU couplers and then fasten the ECU with the band I Fasten the fuel return hose fuel return pipe to sub fuel tank with the plastic lo...

Page 80: ...CABLE ROUTING 2 55 C C B C C A A B D E C L N 1 2 3 4 4 5 5 6 6 7 7 4 5 6 7 8 8 8 9 10 11 11 11 12 14 13 15 16 17 18 19 20 21 22 26 27 A B F G H I J K L M O P Q R S T U V W X 21 23 24 25 28 H F 24 G...

Page 81: ...Align the ends of the hose clamp with the white paint mark on the fuel return hose F Align the paint marks on the hoses with the hose joint as shown in the illustration G Fasten the fuel tank breather...

Page 82: ...CABLE ROUTING 2 57 C C B A B A C C A B D C E F H G I J 1 2 3 4 5 4 5 6 7 8 9 10 11 12 13 11 13 14 15 16 17 18 19 20 22 7 11 11 13 13 11 21 K...

Page 83: ...take air pressure sensor hose onto the throttle body pipe up to the bend in the pipe making sure to face the white paint mark on the hose upward Face the ends of the hose clamp forward C Fasten the ca...

Page 84: ...CABLE ROUTING 2 59 A B B A A B B C D E F G H I J 1 2 3 4 4 5 6 7 8 8 8 9 9 9 10 10 10 11 9 10 12 13 14 15 16 17 18 19 B...

Page 85: ...ke manifold assembly completely onto the intake manifold making sure to face the green paint mark on the hose to the left Face the ends of the hose clamp outward angled 45 forward D Install the cylind...

Page 86: ...CABLE ROUTING 2 61...

Page 87: ...KING THE CYLINDER HEAD BREATHER HOSE 3 17 CHECKING THE OIL TANK BREATHER HOSE 3 17 CHECKING THE EXHAUST SYSTEM 3 17 CHECKING THE CANISTER for California only 3 18 ADJUSTING THE EXUP CABLES 3 18 CHASSI...

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

Page 89: ......

Page 90: ...cks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust valve clear ance wh...

Page 91: ...Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leakage Replace if necessary 18 Shock...

Page 92: ...to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake and clutch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch rele...

Page 93: ...rance is on the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature W...

Page 94: ...bolts do not scratch the rocker arms or other engine parts 11 Measure Valve clearance Out of specification Adjust Piston 1 TDC rear cylinder a Turn the crankshaft counterclockwise b When piston 1 is a...

Page 95: ...earance a Loosen the locknut 1 b Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip c Turn the adjusting screw 3 in direction a or b with the tappet adjusting tool 4 u...

Page 96: ...suitable stand 2 Remove Rider seat Rider seat bracket assembly Refer to GENERAL CHASSIS on page 4 1 Cylinder 1 ignition coil cover Refer to ENGINE REMOVAL on page 5 1 Fuel tank Refer to FUEL TANK on...

Page 97: ...en two throttle bodies should not exceed 1 33 kPa 10 mmHg 8 Stop the engine and remove the measuring equipment 9 Adjust Throttle cable free play Refer to ADJUSTING THE THROTTLE CA BLE FREE PLAY on pag...

Page 98: ...plug CAUTION ECA13320 Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type I...

Page 99: ...iming mark accessing screw 3 4 Connect Timing light 1 Tachometer 5 Check Ignition timing a Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b...

Page 100: ...ed Do not screw the dipstick in when inspecting the oil level CAUTION ECA13380 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not a...

Page 101: ...Replace 9 Install Engine oil drain bolt oil tank along with the gasket 10 Install Engine oil drain bolts crankcase along with the gaskets 11 Fill Oil tank with the specified amount of the recom mended...

Page 102: ...oil filter cartridge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 95 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gal...

Page 103: ...r to CHECKING THE TRANSFER GEAR OIL LEVEL on page 3 13 10 Install Exhaust pipes Muffler Refer to ENGINE REMOVAL on page 5 1 EAS20890 CHECKING THE CLUTCH FLUID LEVEL 1 Stand the vehicle on a level surf...

Page 104: ...siderably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the clutch fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose...

Page 105: ...e 4 1 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 GENERA...

Page 106: ...hose is routed correctly 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 pag...

Page 107: ...Install Horn 1 Refer to THROTTLE BODIES on page 6 6 EAS21100 ADJUSTING THE EXUP CABLES 1 Remove EXUP valve pulley cover 1 2 Check EXUP system operation a Turn the main switch to ON b Check that the E...

Page 108: ...and check that the projection c on the EXUP valve pulley contacts the stoppers fully open and fully closed positions then stops between the lines d on the cable holder 5 Install EXUP valve pulley cov...

Page 109: ...cle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance CAUTION ECA13510 After adjusting the brake pedal position mak...

Page 110: ...e a correct reading of the brake fluid level make sure the top of the brake fluid reservoir is horizontal 4 Install Rider seat Refer to GENERAL CHASSIS on page 4 1 EAS21250 CHECKING THE FRONT BRAKE PA...

Page 111: ...GHT SWITCH NOTE The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect st...

Page 112: ...ress down the brake pedal and hold it in position g Loosen the bleed screw NOTE Loosening the bleed screw will release the pres sure and cause the brake lever to contact the throttle grip or the brake...

Page 113: ...gine is cold and when the drive belt is dry 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over NOTE Place the vehicle on...

Page 114: ...rear wheel axle nut to specifica tion 5 Install Muffler Refer to ENGINE REMOVAL on page 5 1 WARNING EWA12800 Always use a new gasket EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehic...

Page 115: ...lower bearings Refer to STEERING HEAD on page 4 69 e Install the rubber washer 3 f Install the upper ring nut g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary...

Page 116: ...knut 2 b Turn the adjusting ring 3 in direction a or b c Tighten the locknut to specification CAUTION ECA13600 Always tighten the locknut against the ad justing nut and torque it to specification EAS2...

Page 117: ...he correct tube Always replace a new tube tire and a new tube as a set To avoid pinching the tube make sure the wheel rim band and tube are centered in the wheel groove Patching a punctured tube is no...

Page 118: ...E WHEELS The following procedure applies to both of the wheels 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel NOTE After a tire or wheel has...

Page 119: ...1720 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal mo...

Page 120: ...ght coupler 1 b Remove Headlight bulb 2 WARNING EWA13320 Since the headlight bulb gets extremely hot keep flammable products and your hands away from the bulb until it has cooled down c Install Headli...

Page 121: ...oughly clean it with a cloth moistened with alcohol or lacquer thinner f Attach Headlight bulb holder g Connect Headlight coupler h Install Headlight bulb cover 7 Install Headlight assembly 8 Connect...

Page 122: ...ELECTRICAL SYSTEM 3 33 a b 1...

Page 123: ...ECKING THE REAR WHEEL 4 28 CHECKING THE REAR BRAKE CALIPER BRACKET 4 28 CHECKING THE REAR WHEEL DRIVE HUB 4 29 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 29 ASSEMBLING THE REAR WHEEL 4 29 ADJUSTIN...

Page 124: ...EGS 4 64 DISASSEMBLING THE FRONT FORK LEGS 4 64 CHECKING THE FRONT FORK LEGS 4 65 ASSEMBLING THE FRONT FORK LEGS 4 65 INSTALLING THE FRONT FORK LEGS 4 68 STEERING HEAD 4 69 REMOVING THE LOWER BRACKET...

Page 125: ......

Page 126: ...ket left and right 2 4 Windshield brace left and right 2 5 Windshield screen 1 6 Windshield holder bracket assembly left and right 2 For installation reverse the removal proce dure 1 6 T R 23 Nm 2 3 m...

Page 127: ...ent it from falling when removing ET1D71045 ASSEMBLING THE WINDSHIELD 1 Install Windshield lock 1 NOTE Align the projection a on the lock 1 with the slot b in the windshield bracket 2 ET1D71040 INSTAL...

Page 128: ...GENERAL CHASSIS 4 3 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 2 1...

Page 129: ...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 2 Backrest assembly 1 3 Backrest...

Page 130: ...ot b in the left backrest lower bracket 2 2 Install Backrest lower brackets 1 Backrest upper bracket 2 Backrest plate NOTE Before tightening the bolts 3 to specification temporarily install the backre...

Page 131: ...e sure that the lever hook 1 on each side is secure ly fit over its holder 2 WARNING EW1D71017 Both lever hooks must be securely fitted over their holder If the backrest is loose a passenger might los...

Page 132: ...g bracket brace 1 3 Sidebag bracket left and right 2 NOTE Remove only one sidebag bracket at a time If both brackets are removed at the same time the rear fender will fall 4 O2 sensor lead guide 1 NOT...

Page 133: ...D71047 CHECKING THE SIDEBAG BRACKET SPRING NUTS 1 Check Sidebag bracket spring nut height a Out of specification Adjust 2 Check Sidebag bracket spring nuts Damage Replace Sidebag bracket spring nut he...

Page 134: ...ssembly 1 6 Right side cover 1 7 Left side cover 1 8 Seat lock cable assembly 1 For installation reverse the removal proce dure 1 6 2 4 5 7 8 3 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib...

Page 135: ...Headlight lens unit 1 7 Front left turn signal position light coupler 1 Disconnect 8 Front right turn signal position light coupler 1 Disconnect 9 Wire harness stopper bracket 1 10 Left handlebar swit...

Page 136: ...nit 1 3 Coupler tray 1 4 Negative terminal cover 1 5 Negative battery lead 1 Disconnect 6 Positive battery lead 1 Disconnect 7 Battery 1 8 Battery band 1 9 Sub wire harness 1 1 Disconnect 10 Main fuse...

Page 137: ...elay 1 18 Turn signal relay 1 19 Plastic locking tie 2 20 Battery box 1 For installation reverse the removal proce dure Removing the battery Order Job Parts to remove Q ty Remarks 13 18 17 16 15 19 14...

Page 138: ...1 intake air pressure sensor 1 6 Cylinder 1 intake air pressure sensor bracket 1 7 Cylinder 2 intake air pressure sensor coupler 1 Disconnect 8 Cylinder 2 intake air pressure sensor hose 1 Disconnect...

Page 139: ...screw 2 Loosen 17 Air filter case 1 For installation reverse the removal proce dure Removing the air filter case Order Job Parts to remove Q ty Remarks 15 9 7 8 14 16 11 4 3 12 13 16 5 6 1 17 2 10 T R...

Page 140: ...ket 1 7 Front fender 1 8 Reflector 2 9 Reflector bracket 2 10 Front brake caliper 2 11 Front wheel axle pinch bolt 1 Loosen 12 Front wheel axle 1 13 Front wheel 1 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm...

Page 141: ...Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib LT LT LT LT LT LT LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib R 40 Nm 4 0 m kg 29 ft Ib R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m...

Page 142: ...FRONT WHEEL 4 17 Disassembling the front wheel Order Job Parts to remove Q ty Remarks 1 Oil seal 2 2 Wheel bearing 2 3 Spacer 1 For assembly reverse the disassembly pro cedure 2 1 2 1 3 LS LS New New...

Page 143: ...inch bolt 1 4 Remove Front brake calipers NOTE Do not apply the brake lever when removing the brake calipers 5 Elevate Front wheel NOTE Place the vehicle on a suitable stand so that the front wheel is...

Page 144: ...011 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 NOTE Use a socket 4 that matches the diameter of the wheel bearing outer race and oil sea...

Page 145: ...Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is bala...

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