Yamaha XV19SW 2006, Service Manual

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CABLE ROUTING
2-50
1. EXUP servo motor
2. Fuse box
3. Wire harness
4. Fuel outlet hose
5. Cylinder-#1 right spark plug cap
6. Cylinder-#1 right ignition coil
7. Cylinder-#2 intake air pressure sensor coupler
8. Fuel sender (fuel tank) coupler
9. Meter assembly coupler
10. Throttle cable
11. Front brake hose
12. Cylinder-#2 right spark plug cap
13. Cylinder-#1 left ignition coil
14. Clutch pipe
15. Neutral switch lead
16. Stator coil lead
17. Speed sensor lead
18. O
2
sensor lead
19. EXUP cable
20. Cylinder-#1 right spark plug lead
21. Cylinder-#1 left spark plug lead
22. ISC (idle speed control) unit inlet hose
23. Cylinder-#2 ISC (idle speed control) unit outlet
hose
24. Cylinder-#1 ISC (idle speed control) unit outlet
hose
25. Sub-wire harness 3 coupler
26. Cylinder-#2 right spark plug lead
27. Sub-wire harness 4 coupler
28. Cylinder-#2 left spark plug lead
A. Fasten the cylinder-#1 left and right spark plug
leads, fuel outlet hose, wire harness and the fuel
tank damper with the plastic locking tie. Install the
plastic locking tie in the rear slot of the fuel tank
damper.
B. Fasten the fuel outlet hose, wire harness, and fuel
tank damper with the plastic locking tie. Install the
plastic locking tie in the front slot of the fuel tank
damper and make sure that the end of the damper
is aligned with the edge of the flat section on the
outside of the frame.
C. Fasten the cylinder-#1 left and right ignition coil
leads, engine temperature sensor lead, and throttle
position sensor lead to the guide on the engine
bracket (right upper side) with the plastic locking tie.
Face the end of the plastic locking tie rearward, and
then cut off the excess end of the tie.
D. Fasten sub-wire harness 2 with the plastic locking
tie.
E. Align the positioning tape on the wire harness with
the top of the frame.
F. 0
–
15 mm (0
–
0.59 in)
G. Route the throttle cables behind the front 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 and sub-wire
harness 4 coupler on top of the guide.
J. Fasten the wire harness and the cylinder-#2 left
and right spark plug leads with a plastic locking tie,
making sure to install the tie just past the end of the
protective tube of the wire harness. Face the end of
the plastic locking tie inward, and then cut off the
excess end of the tie.
K. To the throttle position sensor
L. To the fuel injector and engine temperature sensor
M. To the neutral switch
N. To the speed sensor
O. Fasten the stator coil lead with the plastic locking
ties. Face the end of each plastic locking tie
outward, and then cut off the excess end of the tie.
P. To the rear brake caliper
Q. Install the O
2
sensor coupler completely onto the
O
2
sensor bracket.
R. Outside of the frame
S. Position the buckle of the plastic locking tie to the
inside of the frame. Face the end of the plastic
locking tie upward, and then cut off the excess end
of the tie.
T. Inside of the frame
U. Position the buckle of the plastic locking tie to the
inside of the frame.
V. To the wire harness
W. To the cylinder-#2 right spark plug
X. Right side
Y. Position the sub-wire harness 3 coupler and the
sub-wire harness 4 coupler between the cylinder-
#2 right spark plug lead and the cylinder-#1 ISC
unit outlet hose.
Z. Face the ends of the hose clamp outward, angled
45
°
downward.
AA.Route the cylinder-#2 right spark plug lead under
the sub-wire harness 4.
AB.Face the ends of the hose clamp downward.
AC.Route the cylinder-#2 left spark plug lead under the
cylinder-#2 ISC unit outlet hose.
AD.Left side
AE.To the cylinder-#2 left spark plug
AF. Install the clutch pipe onto the clutch release
cylinder, making sure that the pipe contacts the
projection on the cylinder.
AG.To the O
2
sensor
AH.Align the cutout in the clutch pipe union bolt cap
with the projection on the clutch release cylinder.