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Yamaha XV19SX(C), Service Manual


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CLUTCH

5-69

EAS25260

INSTALLING THE CLUTCH

1. Install:

• Clutch housing
• Thrust washer

NOTE:

• Lubricate the clutch housing bearings with en-

gine oil.

• Make sure that the primary driven gear teeth 

and primary drive gear teeth mesh correctly.

• Make sure that the primary driven gear teeth 

and oil pump driven gear teeth mesh correctly.

2. Install:

• Clutch boss assembly “1”

NOTE:

• Install the clutch damper spring “2” with the 

“OUTSIDE” mark facing out.

• If the wire circlip “3” has been removed, care-

fully install a new one.

3. Install:

• Clutch boss “1”

• Washer
• Conical spring washer “2”
• Clutch boss nut “3”

NOTE:

• Lubricate the clutch boss nut threads and con-

ical spring washer mating surfaces with engine 
oil.

• Install the conical spring washer “2” with the 

“OUT” mark “a” facing out.

• While holding the clutch boss with the univer-

sal clutch holder “4”, tighten the clutch boss 
nut.

• Stake the clutch boss nut “3” at a cutout “b” in 

the main axle.

4. Lubricate:

• Friction plates
• Clutch plates

(with the recommended lubricant)

5. Install:

• Friction plates 2 “1”
• Clutch plates
• Friction plate 1 “2”

NOTE:

• First, install a friction plate and then alternate 

between a clutch plate and a friction plate.

• Align a projection on each friction plate 2 “1” 

with the “

” mark “a” on the clutch housing 

and align a projection on friction plate 1 “2” with 
the punch mark “b” on the housing.

2

1

3

4

1

2

3

New

T

 

R

.

.

 

Clutch boss nut

105 Nm (10.5 m·kg, 75 ft·lb)

 

Universal clutch holder

90890-04086
YM-91042

 

Recommended lubricant

Engine oil

1

b

4

3

2

a

Summary of Contents for XV19SX(C)

Page 1: ...2008 SERVICE MANUAL XV19SX C XV19MX C XV19CTSX C XV19CTMX C XV19CSX C XV19CX C LIT 11616 21 26 1D7 28197 12...

Page 2: ...X C SERVICE MANUAL 2007 by Yamaha Motor Corporation U S A First edition June 2007 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U...

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: ...page 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: ...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 oil 10 Gear oil 11 Mo...

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: ...NCTIONS 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 1 11 REPLACEMENT PARTS 1 11 GASKETS...

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: ...onically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by using a microproces...

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: ...is 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 and RESET switches except for setting the bri...

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: ...erve 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 and reset swi...

Page 17: ...mately 8 L 2 11 US gal 1 72 Imp gal For the fuel level range that the fuel sender is not able to detect the fuel level is calculated using the distance traveled and preset fuel consump tion values acc...

Page 18: ...and reset switches to gether for at least three seconds 2 When the hour digits start flashing push the reset switch to set the hours 3 Push the SELECT switch and the minute digits will start flashing...

Page 19: ...e key to ON and then release the SELECT switch after five seconds 4 Adjust the multi function meter unit panel brightness level by pushing the reset switch 5 Push the SELECT switch The odometer tripme...

Page 20: ...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 21: ...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 22: ...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 23: ...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 24: ...rench 90890 01403 Spanner wrench YU 33975 3 27 4 81 Damper rod holder 90890 01460 4 71 4 73 T handle 90890 01326 T handle 3 8 drive 60 cm long YM 01326 4 71 4 73 Fork seal driver 90890 01442 Adjustabl...

Page 25: ...6 0 mm YM 04065 A 5 43 Valve guide reamer 6 90890 04066 Valve guide reamer 6 0 mm YM 04066 5 43 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 49 Universal clutch holder 90890 04086 Y...

Page 26: ...pump gauge set 90890 06756 Mityvac brake bleeding tool YS 42423 6 16 Pressure gauge 90890 03153 YU 03153 6 16 Fuel pressure adapter 90890 03176 YM 03176 6 16 Digital circuit tester 90890 03174 Model 8...

Page 27: ...ENING TORQUE SPECIFICATIONS 2 20 ENGINE TIGHTENING TORQUES 2 21 CHASSIS TIGHTENING TORQUES 2 26 LUBRICATION POINTS AND LUBRICANT TYPES 2 33 ENGINE 2 33 CHASSIS 2 35 LUBRICATION SYSTEM CHART AND DIAGRA...

Page 28: ...9CX 29S1 30B1 USA XV19CXC 29S2 30B2 California XV19CX 29S3 30B3 CDN Dimensions Overall length XV19S C XV19M C XV19CTS C XV19CTM C 2580 mm 101 6 in XV19CS C XV19C C 2572 mm 101 3 in Overall width XV19S...

Page 29: ...turning radius XV19S C XV19M C XV19CTS C XV19CTM C 3480 mm 137 0 in XV19CS C XV19C C 3500 mm 137 8 in Weight With oil and fuel XV19S C XV19M C 340 0 kg 750 lb XV19CTS C XV19CTM C 364 0 kg 802 lb XV19C...

Page 30: ...SAE20W40 Recommended engine oil grade API service SG type or higher JASO standard MA Engine oil quantity Total amount 5 20 L 5 50 US qt 4 58 Imp qt Engine 3 2 L 3 38 US qt 2 82 Imp qt Oil tank 2 0 L...

Page 31: ...0 035 in Cylinder head Volume 80 90 84 90 cm 4 94 5 18 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Gear drive Crankcase hole inside diameter 25 000 25 021 mm 0 9843 0 9851 in Camshaft...

Page 32: ...213 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 30 mm 0 0433 0 0512...

Page 33: ...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 Installed compression spring force exhaust 217 00 249 00 N...

Page 34: ...n 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 Piston ring Top ring...

Page 35: ...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 0 122 in Wear limit 2 80 mm 0 110 in Pl...

Page 36: ...de bar Shift fork guide bar bending limit 0 025 mm 0 0010 in Shift fork thickness 6 26 6 39 mm 0 2465 0 2516 in Air filter Air filter element Oil coated paper element Fuel pump Pump type Electrical Mo...

Page 37: ...3 V Fuel injection sensor Crankshaft position sensor resistance 248 372 Intake air pressure sensor output voltage 3 75 4 25 V Engine temperature sensor resistance 0 90 1 10 k at 100 C 212 F Idling con...

Page 38: ...3 50 Rim material Aluminum Wheel travel 130 0 mm 5 12 in Radial wheel runout limit 1 0 mm 0 04 in Lateral wheel runout limit 0 5 mm 0 02 in Rear wheel Wheel type Cast wheel Rim size XV19S C XV19M C XV...

Page 39: ...limit rear 1 0 mm 0 04 in Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 250 kPa 36 psi 2 50 kgf cm Rear 280 kPa 41 psi 2 80 kgf cm Loading condition XV19S C XV19M C...

Page 40: ...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 Master cyl...

Page 41: ...130 0 mm 1 18 5 12 in Inner tube outer diameter 46 0 mm 1 81 in Inner tube bending limit 0 2 mm 0 01 in Optional spring available No Recommended oil Yamaha fork oil 10WT Quantity XV19S C XV19M C XV19...

Page 42: ...g available No Enclosed gas air pressure STD 0 98 MPa 139 4 psi 9 8 kgf cm Spring preload adjusting positions Installed spring length Minimum XV19S C XV19M C XV19CTS C XV19CTM C 162 0 mm 6 38 in XV19C...

Page 43: ...resistance 2 16 2 64 Secondary coil resistance 8 64 12 96 k Spark plug cap Material Resin Resistance 10 0 k AC magneto Model manufacturer F4T38971 MITSUBISHI Standard output 14 0 V 32 0 A 5000 r min...

Page 44: ...rning light LED Electric starting system System type Constant mesh Starter motor Model manufacturer 1D7 YAMAHA Power output 0 90 kW Armature coil resistance 0 0081 0 0099 Brush overall length 9 8 mm 0...

Page 45: ...ITA Fuel pump relay Model manufacturer G8R 30Y V3 OMRON Coil resistance 162 198 Thermo unit Model manufacturer 5PX DENSO Resistance at 100 C 898 4 1098 0 Fuses Main fuse 50 0 A Headlight fuse 20 0 A T...

Page 46: ...ELECTRICAL SPECIFICATIONS 2 19 Spare fuse 3 0 A...

Page 47: ...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 48: ...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 drive gear bolt M10 1 60 Nm 6 0 m kg 43 ft lb Front cyl...

Page 49: ...olt 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 frame bolt 2 M8 1 20 Nm 2 0 m kg 14 ft lb Muffler and muffler bracket bolt 1 M8 3 29 Nm 2...

Page 50: ...m 1 0 m kg 7 2 ft lb Starter clutch bolt M8 6 24 Nm 2 4 m kg 17 ft lb Generator rotor bolt M12 1 80 Nm 8 0 m kg 58 ft lb Starter motor bolt M6 2 10 Nm 1 0 m kg 7 2 ft lb Primary drive gear bolt 1 M12...

Page 51: ...Transfer gear case cover plate bolt M6 3 5 Nm 0 5 m kg 3 6 ft lb Transfer gear case cover bolt M6 12 10 Nm 1 0 m kg 7 2 ft lb Oil tank cover bolt M6 15 10 Nm 1 0 m kg 7 2 ft lb Oil tank bracket bolt...

Page 52: ...TIGHTENING TORQUES 2 25 Cylinder head tightening sequence 3 1 2 4 A B 3 1 2 4 A Front cylinder B Rear cylinder...

Page 53: ...lb Engine mounting nut front lower side 1 2 M12 1 105 Nm 10 5 m kg 75 ft lb Engine mounting nut front lower side 3 M12 1 90 Nm 9 0 m kg 65 ft lb Engine bracket nut front upper side M10 4 53 Nm 5 3 m...

Page 54: ...6 4 7 Nm 0 7 m kg 5 1 ft lb Headlight bracket and throttle ca ble guide bolt 1 2 M6 2 10 Nm 1 0 m kg 7 2 ft lb Headlight body bolt 1 2 M6 3 7 Nm 0 7 m kg 5 1 ft lb Headlight body bolt 3 M6 1 10 Nm 1 0...

Page 55: ...0 m kg 7 2 ft lb Front brake hose guide and lower bracket bolt 1 2 M6 1 10 Nm 1 0 m kg 7 2 ft lb Front brake hose guide and lower bracket bolt 3 M6 1 7 Nm 0 7 m kg 5 1 ft lb Front brake hose joint bo...

Page 56: ...50 Nm 15 0 m kg 110 ft lb Locknut drive belt adjusting bolt M8 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...

Page 57: ...6 2 7 Nm 0 7 m kg 5 1 ft lb Cylinder 1 ignition coil bracket bolt 1 2 M6 2 7 Nm 0 7 m kg 5 1 ft lb Right ignition coil cover bolt 3 M6 2 7 Nm 0 7 m kg 5 1 ft lb Right ignition coil bracket bolt 3 M6 2...

Page 58: ...e bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Throttle cable guide bolt upper side 1 2 M6 1 7 Nm 0 7 m kg 5 1 ft lb Throttle cable guide bolt lower side 1 2 M6 1 10 Nm 1 0 m kg 7 2 ft lb Throttle cable guide bo...

Page 59: ...approximately 52 Nm 5 2 m kg 37 ft lb with a torque wrench then loosen the lower ring nut completely 2 Retighten the lower ring nut to 18 Nm 1 8 m kg 13 ft lb with a torque wrench Sidebag bracket bol...

Page 60: ...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 and exhaust Valve stem ends intake and exhaust...

Page 61: ...spring 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 coil lead gr...

Page 62: ...r pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Brake pedal shaft pivoting point Shift pedal pivoting point Passenger footrest pivoting poi...

Page 63: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 36...

Page 64: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 37 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 65: ...ad 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 sprocket cover 17 Ge...

Page 66: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 39 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 67: ...EM CHART AND DIAGRAMS 2 40 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 68: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 41 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 69: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 42 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 70: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 43 A A A A 1 3 2 4...

Page 71: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 44 1 Oil pipe 1 2 Oil pump 3 Oil strainer crankcase 4 Joint pipe...

Page 72: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 45 A 1 2 3 4...

Page 73: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 46 1 Main axle 2 Drive axle 3 Oil strainer crankcase 4 Oil pump A To the oil filter cartridge...

Page 74: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 47 A A A 1 5 5 1 3 2 4 B B B B...

Page 75: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 48 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 76: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 49 1 2...

Page 77: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 50 1 Transfer gear oil pump 2 Middle driven shaft...

Page 78: ...for XV19S C XV19M C XV19CTS C XV19CTM C 2 51 EAS20430 CABLE ROUTING for XV19S C XV19M C XV19CTS C XV19CTM C 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...

Page 79: ...t and right handlebar 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 lo...

Page 80: ...CABLE ROUTING for XV19S C XV19M C XV19CTS C XV19CTM C 2 53 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 81: ...ht housing D Fasten 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...

Page 82: ...C C C A A J J G G K E 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 A...

Page 83: ...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...

Page 84: ...D D D D A A C B B C 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 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...

Page 85: ...rear brake light switch 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 plas...

Page 86: ...C XV19M C XV19CTS C XV19CTM C 2 59 T A A D D E E C B B B D A C 21 4 20 19 23 16 8 18 22 17 15 4 18 15 16 17 8 L N O E K A M B I H D C E F G E 2 14 1 3 4 5 6 7 8 9 13 12 11 10 P U W 8 5 26 25 24 Q R S...

Page 87: ...e plastic locking tie 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...

Page 88: ...V19S C XV19M C XV19CTS C XV19CTM C 2 61 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...

Page 89: ...White paint mark E 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 th...

Page 90: ...CABLE ROUTING for XV19S C XV19M C XV19CTS C XV19CTM C 2 63 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 91: ...ll the cylinder 1 intake 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 for...

Page 92: ...CABLE ROUTING for XV19S C XV19M C XV19CTS C XV19CTM C 2 65 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 93: ...e hose joint to intake 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...

Page 94: ...CABLE ROUTING for XV19CS C XV19C C 2 67 EAS1D77001 CABLE ROUTING for XV19CS C XV19C C E E F F B B C C A D A A B C C D E E F G 1 1 1 2 2 3 3 3 4 4 4 5 6 5 6 7 8 9 10 A D E E C F F C B B...

Page 95: ...switch lead through the grommet B 5 15 mm 0 20 0 59 in C Fasten the rear brake light switch lead with a plastic locking tie Face the end of the plastic locking tie inward and then cut off the excess...

Page 96: ...CABLE ROUTING for XV19CS C XV19C C 2 69 A B C D E F L G H H I J K N M O 1 1 2 3 3 4 5 6 7 1 7 7 8 9 10 11 E E F F B A C D B A C D E E F F F F...

Page 97: ...Fit the right handlebar switch lead in between the grommet and the main switch cover bracket making sure to push the lead all the way down G Route the main switch lead under the headlight bracket H P...

Page 98: ...OUTING for XV19CS C XV19C C 2 71 D E A C C D E B B A A A B B D D E E C C A B C D E F F G H I J K L M N O O O P Q S S S S T T T T U U V V 1 2 3 3 3 3 3 4 4 4 4 5 6 7 10 11 12 13 14 15 16 17 18 19 19 20...

Page 99: ...harness and meter assembly lead to the frame with plastic locking ties Face the end of each plastic locking tie inward and then cut off the excess end of the tie G Position the plastic locking tie to...

Page 100: ...XV19C C 2 73 B D D B D D C E C A E AC AD AB AE AF A W B C D E F G H I J K L M N O O P P Q R R S S T U V X Y Z 1 2 3 4 5 4 5 6 7 8 9 10 11 12 13 14 15 16 17 17 17 18 19 19 20 21 22 23 24 25 26 27 28 29...

Page 101: ...lead and rectifier regulator lead with a plastic locking tie Face the end of the plastic locking tie outward and then cut off the excess end of the tie M Fasten the lean angle sensor lead starter mot...

Page 102: ...for XV19CS C XV19C C 2 75 A A D D C C B D D A B C B B D E F G H I J K L M N O P Q R S T 1 2 3 4 5 5 5 6 6 7 8 9 9 9 9 10 10 11 12 13 14 15 16 15 16 17 17 18 18 19 19 20 20 21 22 23 24 25 25 26 27 28 2...

Page 103: ...to align the tie with the line on the rubber damper Face the end of the plastic locking tie upward and then cut off the excess end of the tie F Connect the ECU couplers and then fasten the ECU with t...

Page 104: ...ING for XV19CS C XV19C C 2 77 A A B B C C D D A A B B C C D D A B C D E F G H H I J K O L B M N P Q R S T U V 1 2 3 3 3 4 4 4 5 5 5 6 6 6 7 7 7 8 9 10 10 11 11 12 12 13 13 14 14 15 16 16 17 18 18 18 1...

Page 105: ...projections on the clamp are positioned as shown in the illustration E Align the white paint mark on the end of the fuel return hose fuel return pipe to sub fuel tank with the white paint mark on the...

Page 106: ...CABLE ROUTING for XV19CS C XV19C C 2 79 C C C C A B B A A B C C D E F G H I J 1 2 3 4 4 5 5 6 6 7 8 9 9 9 9 9 10 11 11 11 11 12 13 14 15 16 17 18 19 20 FWD...

Page 107: ...2 A Face the ends of the hose clamp to the left angled 45 rearward B Install the cylinder 1 intake air pressure sensor hose onto the throttle body pipe up to the bend in the pipe making sure to face...

Page 108: ...CABLE ROUTING for XV19CS C XV19C C 2 81 B A A B C C D E F B J J 1 2 3 4 5 6 6 7 7 7 8 8 A B G H I 6 7 8 8 9 10 11 12 13 14 FWD...

Page 109: ...joint to intake manifold assembly completely onto the intake manifold making sure to face the pink paint mark on the hose to the left Face the ends of the hose clamp outward angled 45 forward E To the...

Page 110: ...CABLE ROUTING for XV19CS C XV19C C 2 83...

Page 111: ...THE TRANSFER GEAR OIL LEVEL 3 13 CHANGING THE TRANSFER GEAR OIL 3 14 CHECKING THE CLUTCH FLUID LEVEL 3 14 BLEEDING THE HYDRAULIC CLUTCH SYSTEM 3 15 REPLACING THE AIR FILTER ELEMENT 3 15 CHECKING THE T...

Page 112: ...NG AND ADJUSTING THE STEERING HEAD 3 27 CHECKING THE FRONT FORK 3 28 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 28 CHECKING THE TIRES 3 29 CHECKING THE WHEELS 3 31 CHECKING AND LUBRICATING THE CABLE...

Page 113: ......

Page 114: ...s 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 when...

Page 115: ...lithium soap based grease all purpose grease lightly 18 Sidestand switch Check operation and replace if necessary 19 Front fork Check operation and for oil leakage Replace if necessary 20 Shock absorb...

Page 116: ...air to avoid damaging it The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas Hydraulic brake and clutch systems After disassembling the brake or clu...

Page 117: ...sting 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 When the valve cleara...

Page 118: ...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 119: ...Valve clearance 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...

Page 120: ...le on a 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 T...

Page 121: ...tle 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 page 3 8 10 Ins...

Page 122: ...wells with compressed air to prevent it from falling into the cylinders 4 Check Spark plug type Incorrect Change 5 Check Electrode 1 Damage wear Replace the spark plug Insulator 2 Abnormal color Repl...

Page 123: ...Start the engine warm it up for several min utes and then let it run at the specified en gine idling speed b Check that pointer a on the clutch cover is within the firing range b on the crankshaft po...

Page 124: ...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 125: ...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 126: ...ge and the oil pump for damage or leakage Refer to OIL PUMP on page 5 100 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolts to spec...

Page 127: ...xhaust pipes Muffler Refer to ENGINE REMOVAL on page 5 1 EAS20890 CHECKING THE CLUTCH FLUID LEVEL 1 Stand the vehicle on a level surface NOTE Place the vehicle on a suitable stand 2 Check Clutch fluid...

Page 128: ...ary to let the clutch fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic clutch system a Add the recommended clutch fluid t...

Page 129: ...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 130: ...ather 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 o...

Page 131: ...olt 7 Rear exhaust pipe nuts 8 Rear exhaust pipe and muffler bolt 9 Muffler and muffler bracket bolts 10 Muffler bracket and frame bolts 11 Muffler and frame bolt 12 T R Front exhaust pipe nut 20 Nm 2...

Page 132: ...Horn 1 Refer to THROTTLE BODIES on page 6 7 2 Check Canister 1 Canister hose 2 Canister purge hose Canister breather hose 3 Fuel tank breather overflow pipe 4 Cracks damage Replace 3 Install Horn 1 Re...

Page 133: ...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 134: ...sence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance CAUTION ECA13...

Page 135: ...luid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately NOTE In order to ensure a correct reading of the brake fluid level make sure the top of t...

Page 136: ...e hose guide Loose Tighten the guide bolt 5 Hold the vehicle upright and apply the brake several times 6 Check Brake hoses Brake fluid leakage Replace the damaged hose Refer to REAR BRAKE on page 4 47...

Page 137: ...e brake fluid reservoir to the proper level with the recommended brake fluid b Install the diaphragm brake master cylinder reservoir or brake fluid reservoir c Connect a clear plastic hose 1 tightly t...

Page 138: ...oint on both ends of the shift rod is 10 mm or less for XV19S C XV19M C XV19CTS C XV19CTM C Make sure that the exposed thread length c between the locknut and joint on both ends of the shift rod is 7...

Page 139: ...ve belt slack a Out of specification Adjust NOTE The level marks of the level window on the low er drive belt cover are in units of 5 mm 0 20 in Use them as a standard for measuring the drive belt sla...

Page 140: ...itable stand so that the front wheel is elevated 2 Check Steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove Upper...

Page 141: ...ts b 5 Install Upper bracket Refer to FRONT FORK on page 4 66 EAS21530 CHECKING THE FRONT FORK 1 Stand the vehicle on a level surface WARNING EWA13120 Securely support the vehicle so that there is no...

Page 142: ...passenger and ac cessories and the anticipated riding speed Operation of an overloaded vehicle could cause tire damage an accident or an injury NEVER OVERLOAD THE VEHICLE Direction a Spring preload is...

Page 143: ...lacement WARNING EWA14090 After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires Tire air pressure measured on cold tires Loadin...

Page 144: ...balance the wheel EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in ner and outer cables WARNING EWA13270 Damaged outer cable may cause the cable to corrode...

Page 145: ...al EAS21720 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 m...

Page 146: ...ght bulb a Disconnect Headlight 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...

Page 147: ...ght bulb gets soiled thoroughly 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 Head...

Page 148: ...hol or lacquer thinner 7 Attach Headlight bulb holder 8 Install Headlight bulb cover 9 Connect Headlight coupler 10 Install Headlight lens unit EAS21810 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headligh...

Page 149: ...ELECTRICAL SYSTEM 3 36 A For XV19S C XV19M C XV19CTS C XV19CTM C B For XV19CS C XV19C C a b 1 A b a B 1...

Page 150: ...ELECTRICAL SYSTEM 3 37...

Page 151: ...ECKING THE REAR WHEEL 4 32 CHECKING THE REAR BRAKE CALIPER BRACKET 4 32 CHECKING THE REAR WHEEL DRIVE HUB 4 33 CHECKING AND REPLACING THE REAR WHEEL PULLEY 4 33 ASSEMBLING THE REAR WHEEL 4 33 ADJUSTIN...

Page 152: ...FRONT FORK LEGS 4 71 CHECKING THE FRONT FORK LEGS 4 72 ASSEMBLING THE FRONT FORK LEGS 4 72 INSTALLING THE FRONT FORK LEGS for XV19S C XV19M C XV19CTS C XV19CTM C 4 75 INSTALLING THE FRONT FORK LEGS fo...

Page 153: ...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...

Page 154: ...nd 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 kg 17 ft...

Page 155: ...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 156: ...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 1...

Page 157: ...e 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 upper...

Page 158: ...t 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 backres...

Page 159: ...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 160: ...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 NOTE Pass th...

Page 161: ...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 162: ...sembly 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 163: ...pler 1 Disconnect 6 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...

Page 164: ...ion light coupler 1 Disconnect 5 Main switch coupler 2 Disconnect 6 Headlight body 1 7 Air temperature sensor coupler 1 Disconnect 8 Air temperature sensor bracket 1 9 Air temperature sensor 1 10 Head...

Page 165: ...ler 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 1 11 Plasti...

Page 166: ...dlight relay 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...

Page 167: ...connect 5 Cylinder 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...

Page 168: ...filter case 1 For installation reverse the removal proce dure Removing the air filter case for XV19S C XV19M C XV19CTS C XV19CTM C Order Job Parts to remove Q ty Remarks 15 9 7 8 14 16 11 4 3 12 13 16...

Page 169: ...e sensor coupler 1 Disconnect 7 Cylinder 1 intake air pressure sensor hose 1 Disconnect 8 Cylinder 1 intake air pressure sensor 1 9 Cylinder 1 intake air pressure sensor bracket 1 10 Cylinder 2 intake...

Page 170: ...filter case bracket 1 21 Air filter case joint clamp screw 2 Loosen 22 Air filter case 1 For installation reverse the removal proce dure Removing the air filter case for XV19CS C XV19C C Order Job Pa...

Page 171: ...hose guide bracket 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...

Page 172: ...y Remarks T R 7 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 T R 40 Nm 4 0 m kg 29 ft Ib T R 23 Nm 2 3 m kg 17 ft...

Page 173: ...ector 2 6 Reflector bracket 2 7 Front brake caliper 2 8 Front wheel axle pinch bolt 1 Loosen 9 Front wheel axle 1 10 Front wheel 1 11 Collar 2 12 Front brake disc 2 For installation reverse the remova...

Page 174: ...FRONT WHEEL 4 21 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 175: ...n Front wheel axle pinch 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 tha...

Page 176: ...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 177: ...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...

Page 178: ...TE Temporarily tighten the front fender bolts Apply locking agent LOCTITE to the threads of the front fender bolts 8 Install for XV19S C XV19M C XV19CTS C XV19CTM C Front fender stay rod 1 Left front...

Page 179: ...FRONT WHEEL 4 26...

Page 180: ...Sub wire harness 1 coupler 1 Disconnect 2 Rear fender bracket 2 For XV19S C XV19M C XV19CTS C XV19CTM C 3 Rear fender bracket 2 For XV19CS C XV19C C 4 Dowel pin 4 5 Rear fender assembly 1 For installa...

Page 181: ...r 1 3 Rear brake pad 2 4 Brake pad spring 2 5 Drive belt adjusting locknut 2 Loosen 6 Drive belt adjusting bolt 2 Loosen 7 Rear wheel axle nut 1 8 Washer 1 9 Rear wheel axle 1 10 Right drive belt pull...

Page 182: ...tion reverse the removal proce dure Removing the rear wheel Order Job Parts to remove Q ty Remarks T R 7 Nm 0 7 m kg 5 1 ft Ib T R 27 Nm 2 7 m kg 19 ft Ib T R 150 Nm 15 0 m kg 110 ft lb 12 9 4 2 4 3 1...

Page 183: ...to remove Q ty Remarks 1 Rear brake disc cover 1 2 Rear brake disc 1 3 Rear wheel pulley 1 4 Oil seal 1 5 Circlip 1 6 Rear wheel drive hub 1 7 Circlip 1 8 Bearing 1 9 Collar 1 10 Bearing 1 11 Rear whe...

Page 184: ...4 31 Disassembling the rear wheel Order Job Parts to remove Q ty Remarks 1 Collar 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly pro cedure 6 4 3 2...

Page 185: ...move the drive belt from the rear wheel pulley EAS22080 DISASSEMBLING THE REAR WHEEL 1 Remove Oil seals Wheel bearings Refer to DISASSEMBLING THE FRONT WHEEL on page 4 22 EAS22090 CHECKING THE REAR WH...

Page 186: ...NT WHEEL on page 4 23 EAS22150 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance...

Page 187: ...t slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 26 6 Tighten Rear wheel axle nut 7 Install Rear brake caliper WARNING EWA13500 Make sure the brake hose is routed properly T R Rear wheel axle...

Page 188: ...e front brake calipers 1 Brake hose holder 1 2 Reflector 1 3 Reflector bracket 1 4 Front brake caliper 1 5 Brake pad clip 2 6 Brake pad pin 1 7 Brake pad spring 1 8 Brake pad 2 9 Brake pad shim 2 For...

Page 189: ...cylinder reservoir diaphragm hold er 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Brake light switch connector 2 Disconnect 7 Brake light switch 1 8 Front brake hose union bolt 1...

Page 190: ...ing the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly p...

Page 191: ...rain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 1 Brake hose holder 1 2 Front brake hose union bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Reflector 1 6 Reflector bracket 1 7 Front...

Page 192: ...wing procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake caliper piston 4 7 Brake caliper piston du...

Page 193: ...ve Front wheel Refer to FRONT WHEEL on page 4 18 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake d...

Page 194: ...a set 2 Install Brake pad shims onto the brake pads Brake pads Brake pad spring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tigh...

Page 195: ...hose holder 1 Front brake hose union bolt 2 Copper washers 3 Front brake hose 4 NOTE Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22350 DISASSEMBLING THE F...

Page 196: ...al brake com ponents as they will cause the piston seals and dust seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals and dust seals EAS22440 INS...

Page 197: ...ntly lower the boiling point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid im...

Page 198: ...AS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Front brake master cylinder 1 Front brake master cylinder holder 2 NOTE Align the end of the brake master cylinder hold er with the punch m...

Page 199: ...ng be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock CAUTION ECA13540 Brake flui...

Page 200: ...ake pads Order Job Parts to remove Q ty Remarks 1 Rear brake caliper bolt 2 2 Rear brake caliper 1 3 Rear brake pad 2 4 Brake pad spring 2 For installation reverse the removal proce dure S 1 2 4 4 3 1...

Page 201: ...ose 1 6 Rear brake master cylinder cover 1 7 Rear brake hose union bolt 1 8 Copper washer 2 9 Rear brake hose 1 10 Rear brake light switch 1 11 Right rider footrest assembly 1 For XV19S C XV19M C XV19...

Page 202: ...ce dure Removing the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 10 13 16 9 6 8 14 15 11 12 5 2 3 4 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 23 Nm 2 3 m kg...

Page 203: ...ylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Circlip 1 5 Brake hose joint 1 6 O ring 1 7 Brake master cylinder body 1 For assembly reverse t...

Page 204: ...in Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 24 1 Rear brake hose union bolt 1 2 Copper washer 2 3 Rear brake hose 1 4 Rear brake caliper bolt 2 5 Rear brake caliper 1 For installation re...

Page 205: ...caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 For assembly reverse the disassembly pro cedure...

Page 206: ...page 4 27 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE D...

Page 207: ...22590 REMOVING THE REAR BRAKE CALIPER NOTE Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Rear brake hose union bolt 1 Copper washers 2 Rear brake h...

Page 208: ...cause the piston seal and dust seal to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seal and dust seal EAS22670 INSTALLING THE REAR BRAKE CALIPER 1 Insta...

Page 209: ...or lock CAUTION ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAK...

Page 210: ...09 When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection a on the brake caliper bracket as shown 2 Fill Brake fluid reservoir with the specified...

Page 211: ...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 on page 3 21 7 Adjust Rear brake light operation...

Page 212: ...ont brake master cylinder assembly 1 6 Throttle cable holder 1 7 Right handlebar switch 1 8 Throttle cable 2 9 Grip end 2 10 Throttle grip 1 11 Clutch switch coupler 1 Disconnect 12 Clutch master cyli...

Page 213: ...al proce dure Removing the handlebar for XV19S C XV19M C XV19CTS C XV19CTM C Order Job Parts to remove Q ty Remarks 1 5 13 18 14 17 15 12 14 11 7 9 4 7 8 19 2 2 3 16 9 1 6 10 LT LT T R 10 Nm 1 0 m kg...

Page 214: ...e master cylinder holder 1 6 Front brake master cylinder assembly 1 7 Throttle cable holder 1 8 Right handlebar switch 1 9 Throttle cable 2 10 Grip end 2 11 Throttle grip 1 12 Clutch switch coupler 1...

Page 215: ...rse the removal proce dure Removing the handlebar for XV19CS C XV19C C Order Job Parts to remove Q ty Remarks T R 10 Nm 1 0 m kg 7 2 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 28 Nm 2 8 m kg 20 ft Ib T R 1...

Page 216: ...e cable decelerator cable 1 to the right handlebar switch 2 NOTE Rotate the right handlebar switch and screw it onto the end of the throttle cable 3 Pass the left and right handlebar switch leads thro...

Page 217: ...ebar switch 1 Grip end 2 NOTE Align the projection a on the right handlebar switch with the hole b in the handlebar There should be 1 3 mm 0 04 0 12 in of clearance c between the throttle grip and the...

Page 218: ...HANDLEBAR 4 65 Throttle cable free play 4 0 6 0 mm 0 16 0 24 in...

Page 219: ...age 4 18 1 Upper bracket cover 1 2 Upper bracket pinch bolt 4 Loosen 3 Cap bolt 1 Loosen 4 Steering stem nut 1 5 Upper bracket 1 6 Upper front fork cover 1 7 Upper front fork cover spacer 1 8 Upper fr...

Page 220: ...r XV19S C XV19M C XV19CTS C XV19CTM C Order Job Parts to remove Q ty Remarks 1 5 6 7 8 11 3 12 9 2 10 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 115 Nm 11 5 m kg 85 ft lb T R 16 Nm 1...

Page 221: ...fer to FRONT WHEEL on page 4 18 1 Upper bracket pinch bolt 4 Loosen 2 Cap bolt 2 Loosen 3 Lower bracket pinch bolt 4 Loosen 4 Front fork leg 2 For installation reverse the removal proce dure 1 1 1 1 4...

Page 222: ...9C C 2 Cap bolt 1 3 O ring 1 4 Spacer 1 5 Spring seat 1 6 Fork spring 1 7 Dust seal 1 8 Oil seal clip 1 9 Damper rod bolt 1 10 Copper washer 1 11 Damper rod 1 12 Rebound spring 1 13 Inner tube 1 14 Oi...

Page 223: ...20 Outer tube 1 For assembly reverse the disassembly pro cedure Disassembling the front fork legs Order Job Parts to remove Q ty Remarks 7 8 14 15 13 17 18 19 10 9 20 1 16 6 11 12 2 3 4 5 T R 23 Nm 2...

Page 224: ...n ing the fork oil 2 Remove Dust seal 1 Oil seal clip 2 with a flathead screwdriver CAUTION ECA14180 Do not scratch the inner tube 3 Remove Damper rod bolt 1 Copper washer NOTE While holding the dampe...

Page 225: ...Cap bolt O ring Damage wear Replace EAS23020 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING EWA13660 Make sure the oil levels in both front fork...

Page 226: ...14220 Make sure the numbered side of the oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap based grease Lubricate the outer surface of the inner tube with fork...

Page 227: ...eep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil 12 Install Spring 1 Spring seat 2 Spacer Cap bolt with O ring NOTE Install the spring with the smalle...

Page 228: ...fork cover 1 with the lower front fork cover nut 2 6 Tighten Steering stem nut Cap bolt Upper bracket pinch bolts NOTE Tighten the upper bracket pinch bolts to specifi cation twice Tighten the upper a...

Page 229: ...is flush with the top of the upper bracket 2 Tighten Lower bracket pinch bolts 3 Tighten Cap bolt Upper bracket pinch bolts NOTE Tighten the upper bracket pinch bolts to specifi cation twice Tighten t...

Page 230: ...1 Headlight bracket and throttle cable guide 1 2 Front brake hose guide 1 3 Front brake hose joint 1 4 Lock washer 1 5 Upper ring nut 1 6 Rubber washer 1 7 Lower ring nut 1 8 Lower bracket 1 9 Upper...

Page 231: ...ng the lower bracket for XV19S C XV19M C XV19CTS C XV19CTM C Order Job Parts to remove Q ty Remarks 8 1 3 2 12 11 13 13 10 9 7 6 5 4 LS LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18 Nm 1 8 m kg 13 ft I...

Page 232: ...de 1 7 Front turn signal position light 2 8 Main switch cover bracket 1 9 Cable guide 1 10 Main switch 1 11 Steering stem bolt 1 12 Washer 1 13 Upper bracket 1 14 Lock washer 1 15 Upper ring nut 1 18...

Page 233: ...oving the lower bracket for XV19CS C XV19C C Order Job Parts to remove Q ty Remarks 18 7 7 5 4 6 3 2 1 22 21 23 23 20 19 17 16 15 14 9 10 12 13 8 11 LS LS LS LS T R 1st 52 Nm 5 2 m kg 37 ft lb 2nd 18...

Page 234: ...s from the steering head pipe with a long rod 1 and hammer b Remove the bearing race from the lower bracket with a floor chisel 2 and hammer c Install a new dust seal and new bearing rac es CAUTION EC...

Page 235: ...STEERING HEAD for XV19CS C XV19C C 1 Lubricate Upper bearing Lower bearing Bearing races 2 Install Lower ring nut 1 Rubber washer 2 Upper ring nut 3 Lock washer 4 Refer to CHECKING AND ADJUSTING THE S...

Page 236: ...sconnect 2 Horn 1 1 3 Passenger footrest left and right 2 For XV19S C XV19M C only 4 O2 sensor lead guide 1 NOTE Pass the O2 sensor lead through the guide For XV19S C XV19M C XV19CTS C XV19CTM C 5 Rea...

Page 237: ...ation reverse the removal proce dure Removing the rear shock absorber assembly and swingarm Order Job Parts to remove Q ty Remarks 8 2 9 12 11 10 8 T R 59 Nm 5 9 m kg 43 ft Ib T R 125 Nm 12 5 m kg 90...

Page 238: ...necting arm 2 6 O ring 4 7 Spacer 1 8 Bushing 4 9 Self locking nut Washer Bolt 1 2 1 10 Rear shock absorber 1 11 Relay arm 1 12 Oil seal Spacer Bearing 2 1 1 13 Oil seal Spacer Bearing 2 1 2 14 Collar...

Page 239: ...SORBER ASSEMBLY AND SWINGARM 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 a suitable sta...

Page 240: ...m Damage wear Replace 2 Check Bearings Oil seals Damage pitting Replace 3 Check Bushings Damage wear Replace 4 Check Spacers Collars Damage scratches Replace EAS23360 CHECKING THE SWINGARM 1 Check Swi...

Page 241: ...b in the bushings are within the areas shown in the illus tration 5 Install Connecting arms Rear shock absorber assembly to relay arm Relay arm to the swingarm NOTE Be sure to face the FWD mark a on...

Page 242: ...it does not drop down 5 Tighten Pivot shaft nut Engine mounting nut rear lower side Connecting arm nut front side 6 Adjust Drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK on page 3 26 T R Con...

Page 243: ...1 2 Lead cover 1 3 Stator coil coupler 1 Disconnect 4 Rectifier regulator coupler 1 Disconnect 5 Rectifier regulator 1 6 Drive pulley cover 1 7 Slider 2 8 Dowel pin 2 9 Transfer gear case bracket 1 1...

Page 244: ...rive belt and drive pulley Order Job Parts to remove Q ty Remarks LT 7 8 13 12 11 10 9 6 1 2 4 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 63 Nm 6 3 m kg 45 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 10 Nm 1 0 m kg 7...

Page 245: ...ive belt thoroughly dry 2 Check Drive belt CAUTION ECA14690 To protect the drive belt from damage han dle it with care The drive belt can not be bent smaller than 127 mm 5 in a The removed drive belt...

Page 246: ...L on page 4 27 4 Tighten Drive pulley nut NOTE When tightening the drive pulley nut press down on the brake pedal so the drive pulley does not move Stake the drive pulley nut 1 at a cutout a in the mi...

Page 247: ...NG 5 29 CHECKING THE OIL DELIVERY PIPE 5 30 INSTALLING THE CAMSHAFTS 5 30 BLEEDING A VALVE LIFTER 5 32 INSTALLING THE VALVE LIFTERS 5 33 INSTALLING THE ROCKER ARMS AND PUSH RODS 5 34 INSTALLING THE CY...

Page 248: ...ALLING THE CLUTCH MASTER CYLINDER 5 71 REMOVING THE CLUTCH RELEASE CYLINDER 5 72 CHECKING THE CLUTCH RELEASE CYLINDER 5 72 ASSEMBLING THE CLUTCH RELEASE CYLINDER 5 73 INSTALLING THE CLUTCH RELEASE CYL...

Page 249: ...ELIEF VALVE 5 103 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 5 103 CHECKING THE OIL STRAINER 5 104 ASSEMBLING THE OIL PUMP 5 104 INSTALLING THE OIL PUMP 5 105 CRANKSHAFT 5 106 REMOVING THE CONNE...

Page 250: ...ect 7 Muffler bracket 1 8 Muffler 1 9 Gasket 1 10 Rear exhaust pipe cover 1 11 Rear exhaust pipe 1 12 Gasket 2 13 O2 sensor 1 14 Front exhaust pipe 1 S 5 10 11 12 14 1 2 12 13 6 4 New New New New New...

Page 251: ...marks S 5 10 11 12 14 1 2 12 13 6 4 New New New New New LT LT LT LT 15 8 9 3 T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0...

Page 252: ...onnect 7 O2 sensor 1 8 Rear exhaust pipe cover 1 9 Rear exhaust pipe 1 10 Gasket 1 11 Gasket 1 12 Front exhaust pipe 1 13 Gasket 1 For installation reverse the removal proce dure 13 12 11 1 9 5 10 8 7...

Page 253: ...DRIVE on page 4 90 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL on page 3 14 Starter motor Refer to ELECTRIC STARTER...

Page 254: ...haft 1 18 Sidestand switch 1 19 Sidestand 1 For installation reverse the removal proce dure Removing the cylinder 1 ignition coils and sidestand for XV19S C XV19M C XV19CTS C XV19CTM C Order Job Parts...

Page 255: ...on page 4 47 Drive pulley Refer to BELT DRIVE on page 4 90 Engine oil Drain Refer to CHANGING THE ENGINE OIL on page 3 11 Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL on page 3 14 S...

Page 256: ...embly 1 14 Sidestand switch 1 15 Sidestand 1 For installation reverse the removal proce dure Removing the right ignition coils and sidestand for XV19CS C XV19C C Order Job Parts to remove Q ty Remarks...

Page 257: ...toe side with the mark b on the heel side 2 Install for XV19S C XV19M C XV19CTS C XV19CTM C Shift pedal assembly 1 NOTE Align the mark a on the shift pedal shaft with the slot in the shift pedal 3 Adj...

Page 258: ...19S C XV19M C XV19CTS C XV19CTM C 5 Oil cooler bracket 1 For XV19S C XV19M C XV19CTS C XV19CTM C 6 Oil filter bolt 1 7 Oil filter bracket 1 For installation reverse the removal proce dure LS LS LS T R...

Page 259: ...9CTS 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 screwdriv...

Page 260: ...Lead holder bracket 1 6 Wire harness guide 1 7 Throttle cable guide 1 8 Starter motor lead 1 9 Horn 2 lead 1 10 Rear brake light switch lead 1 11 Sidestand switch lead 1 12 Crankshaft position sensor...

Page 261: ...tion reverse the removal proce dure Disconnecting the leads Order Job Parts to remove Q ty Remarks 3 2 7 1 10 8 9 5 11 6 LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m...

Page 262: ...mounting bolt front upper side 1 9 Engine cross member bracket bolt 2 10 Engine cross member bracket 1 11 Engine bracket nut front upper side 4 12 Engine bracket bolt front upper side 4 13 Engine brac...

Page 263: ...1 23 Engine mounting bolt rear lower side 1 24 Washer 1 25 Engine 1 For installation reverse the removal proce dure Removing the engine Order Job Parts to remove Q ty Remarks 8 19 2 LT 12 13 11 9 10...

Page 264: ...ricate the engine mounting bolt front lower side threads and nut with engine oil Apply locking agent LOCTITE to the threads of the engine mounting bolts left up per side Do not fully tighten the bolts...

Page 265: ...n Engine bracket nuts front upper side 3 Engine cross member bracket bolts 5 Engine mounting nut front upper side 7 T R Engine mounting nut rear lower side 98 Nm 9 8 m kg 71 ft lb Engine mounting nut...

Page 266: ...ect 2 Spark plug 4 3 Shift pedal assembly 1 For XV19S C XV19M C XV19CTS C XV19CTM C 4 Damper cover 1 5 Damper 1 6 Timing mark accessing screw 1 7 Crankshaft end screw 1 8 Camshaft sprocket cover 1 9 D...

Page 267: ...1 5 Fuel outlet hose 1 Disconnect 6 Cylinder head cover bolt 8 l 40 mm 1 57 in 7 Cylinder head cover bolt 20 l 60 mm 2 36 in 8 Rear cylinder head cover 1 9 Front cylinder head cover 1 10 Cylinder hea...

Page 268: ...g 6 Pull rod 2 1 l 288 5 mm 11 358 in sky blue painting 7 Rocker arm shaft 4 8 Rocker arm 1 2 9 Rocker arm 2 2 10 Locknut 4 11 Adjusting screw 4 12 Rear rocker arm base 1 13 Front rocker arm base 1 Fo...

Page 269: ...page 5 48 1 Push rod cover 2 2 O ring 2 3 O ring 2 4 Seal 2 5 Rear valve lifter case 1 6 Front valve lifter case 1 7 Valve lifter 4 For installation reverse the removal proce dure 1 7 3 5 6 2 1 4 3 2...

Page 270: ...t gear 1 9 Straight key 1 10 Right balancer driven gear 1 11 Straight key 1 12 Camshaft drive gear 1 13 Right balancer drive gear 1 14 Straight key 1 15 Oil delivery pipe 1 1 16 Camshaft cover 1 17 Ca...

Page 271: ...e removal proce dure Removing the camshafts and right balancer Order Job Parts to remove Q ty Remarks New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 60 Nm...

Page 272: ...o remove Q ty Remarks 1 Circlip 2 2 Washer 2 3 Decompression cam spring 2 4 Decompression cam 2 5 Decompression pin 2 6 Front cylinder camshaft 1 7 Rear cylinder camshaft 1 For assembly reverse the di...

Page 273: ...hen piston 1 is at TDC on the compres sion stroke align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch cover c Check the camshaft drive gear mark c posi tion a...

Page 274: ...osen Camshaft drive gear bolt 1 Right balancer driven gear bolt 2 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...

Page 275: ...the camshaft Camshaft lobe dimensions Intake A 42 532 42 632 mm 1 6745 1 6784 in Limit 42 432 mm 1 6705 in Intake B 35 950 36 050 mm 1 4154 1 4193 in Limit 35 850 mm 1 4114 in Exhaust A 42 530 42 630...

Page 276: ...eck Camshaft drive gears Camshaft driven gears Front cylinder camshaft gears Rear cylinder camshaft gears Chips pitting roughness wear Replace the defective part s EAS23890 CHECKING THE ROCKER ARMS AN...

Page 277: ...Push rod Push rod end Bends damage Replace 2 Measure Push rod runout Out of specification Replace EAS23920 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1 Check Valve lifter Blue discoloration ex...

Page 278: ...t the decompression cam 2 and de compression pin 1 moves smoothly 2 Check Decompression cam Decompression pin Damage wear Replace ET1D71031 CHECKING THE DECOMPRESSION CAM SPRING The following procedur...

Page 279: ...keys Right balancer drive gear 1 Right balancer driven gear 2 Camshaft driven gear NOTE Cover the crankcase hole with a clean rag to prevent the straight keys from falling into the crankcase Align th...

Page 280: ...Circlip 6 NOTE Align the projection a on the washer 3 with the punch mark b on the front cylinder cam shaft gear Install the conical spring washer 4 as shown in the illustration Lubricate the front cy...

Page 281: ...the camshaft drive and camshaft driven gears EAS24050 BLEEDING A VALVE LIFTER A valve lifter must be bled in the following cases When installing a new valve lifter When the valve lifter leaks oil 1 Bl...

Page 282: ...allow the valve lift er to bleed j If necessary repeat steps h and i to bleed other valve lifters EAS24060 INSTALLING THE VALVE LIFTERS 1 Install Front valve lifter case Rear valve lifter case Valve l...

Page 283: ...ods be tween the rocker arms and valve lifters as shown The illustration is viewed from the right side of the vehicle The lengths of push rod 1 and push rod 2 are different Therefore be sure to instal...

Page 284: ...e installed when the cover is in place Set the bolts in the cylinder head cover and then install the cover from the right side of the vehicle Bolts 4 l 40 mm 1 57 in Bolts 5 l 60 mm 2 36 in ET1D71032...

Page 285: ...4 Oil pipe 1 1 5 Copper washer 4 6 Copper washer 2 7 Rear cylinder head 1 8 Front cylinder head 1 9 Cylinder head gasket 2 10 Dowel pin 4 11 Rear exhaust pipe joint cover 1 12 Rear exhaust pipe joint...

Page 286: ...Remarks 4 13 3 8 9 10 1 11 5 2 12 7 9 5 6 10 T R 20 Nm 2 0 m kg 14 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0...

Page 287: ...lve seats 2 Check Cylinder head Damage scratches Replace 3 Measure Cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge and a thickness gauge across the cylind...

Page 288: ...fication 5 Install Engine bracket right upper side Engine bracket bolts right upper side Engine mounting bolts right upper side Engine bracket left upper side Engine bracket bolts left upper side Engi...

Page 289: ...C XV19CTS C XV19CTM C 59 Nm 5 9 m kg 43 ft lb XV19CS C XV19C C 66 Nm 6 6 m kg 48 ft lb Engine mounting bolt left upper side 66 Nm 6 6 m kg 48 ft lb LOCTITE Engine bracket bolt right upper side 53 Nm 5...

Page 290: ...dure applies to both cyl inders Cylinder heads Refer to CYLINDER HEADS on page 5 36 1 Valve cotter 8 2 Upper spring seat 4 3 Valve spring 4 4 Intake valve 2 5 Exhaust valve 2 6 Valve stem seal 4 7 Low...

Page 291: ...rs by compressing the valve springs with the valve spring compressor set 1 3 Remove Upper spring seat 1 Valve spring 2 Valve 3 Valve stem seal 4 Lower spring seat 5 NOTE Identify the position of each...

Page 292: ...guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem end Mushroom shape or diameter larger than th...

Page 293: ...head a Apply Mechanic s blueing dye Dykem b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion...

Page 294: ...ove steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s blueing dye Dykem b onto the valve face h Install the v...

Page 295: ...Valve stem seal 2 with the recommended lubricant 3 Install Valve guide 1 Lower spring seat 2 Valve stem seal 3 Valve 4 Valve spring 5 Upper spring seat 6 into the cylinder head Installed compression...

Page 296: ...Valve cotters NOTE Install the valve cotters by compressing the valve springs with the valve spring compressor set 1 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a...

Page 297: ...marks Cylinder heads Refer to CYLINDER HEADS on page 5 36 1 Front cylinder 1 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 5 Circlip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil...

Page 298: ...a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24410 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cy...

Page 299: ...lace 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 2 Install Piston ring into th...

Page 300: ...of specification Replace the piston pin and piston as a set EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis tons and cylinders 1 Install Top ring 1 2nd...

Page 301: ...ing into the crankcase Install the piston pin clips so that the clip ends are 3 mm 0 12 in b or more from the cutout in the piston Reinstall each piston into its original cylinder numbering order star...

Page 302: ...assembly Shift rod Sidestand Refer to ENGINE REMOVAL on page 5 1 Generator cover Refer to GENERATOR AND STARTER CLUTCH on page 5 77 Drive pulley case Refer to TRANSFER GEAR CASE on page 5 86 1 Cranks...

Page 303: ...ket 1 8 Dowel pin 2 For installation reverse the removal proce dure Removing the clutch cover Order Job Parts to remove Q ty Remarks 8 6 7 8 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft...

Page 304: ...Remarks 1 Oil seal 1 2 Bearing 1 3 Clutch cover damper plate 1 4 Clutch cover damper 1 5 Crankshaft position sensor lead holder 3 6 Crankshaft position sensor 1 For installation reverse the removal p...

Page 305: ...n plate 2 9 9 Clutch boss nut 1 10 Conical spring washer 1 11 Washer 1 12 Wire circlip 1 13 Clutch plate 1 14 Friction plate 3 1 Inside diameter 135 mm 5 31 in 15 Clutch damper spring 1 16 Clutch damp...

Page 306: ...Spacer 1 30 Crankshaft position sensor rotor 1 31 Primary drive gear 1 32 Straight key 1 Removing the clutch Order Job Parts to remove Q ty Remarks E 7 8 6 21 20 22 23 27 28 26 25 23 19 24 18 17 16 1...

Page 307: ...oval proce dure Removing the clutch Order Job Parts to remove Q ty Remarks E 7 8 6 21 20 22 23 27 28 26 25 23 19 24 18 17 16 15 14 13 12 10 9 11 3 2 1 4 5 29 30 31 33 32 6 T R 8 Nm 0 8 m kg 5 8 ft Ib...

Page 308: ...ear shaft 1 6 Left balancer drive gear 1 7 Straight key 1 8 Left balancer driven gear 1 9 Left balancer weight 1 1 10 Left balancer weight 2 1 11 Left balancer driven gear housing 1 12 Gasket 1 For in...

Page 309: ...eservoir diaphragm holder 1 4 Clutch master cylinder reservoir diaphragm 1 5 Clutch lever 1 6 Clutch master cylinder push rod pin 1 7 Clutch switch coupler 1 Disconnect 8 Clutch switch 1 9 Clutch hose...

Page 310: ...der Order Job Parts to remove Q ty Remarks 1 Clutch master cylinder push rod 1 2 Dust boot 1 3 Circlip 1 4 Washer 1 5 Clutch master cylinder kit 1 6 Clutch master cylinder body 1 For assembly reverse...

Page 311: ...15 Muffler Exhaust pipes Refer to ENGINE REMOVAL on page 5 1 1 Clutch pipe union bolt cap 1 2 Clutch pipe union bolt 1 3 Copper washer 2 4 Clutch pipe 1 5 Clutch release cylinder 1 6 Dowel pin 2 For...

Page 312: ...Q ty Remarks 1 Boots 1 2 Clutch release cylinder piston 1 3 Clutch release cylinder spring 1 4 Clutch release cylinder piston seal 1 5 Bleed screw 1 6 Clutch release cylinder body 1 For assembly reve...

Page 313: ...nless there is serious clutch chattering EAS25090 REMOVING THE PRIMARY DRIVE GEAR 1 Loosen Primary drive gear bolt 1 NOTE While holding the generator rotor 2 with the sheave holder 3 loosen the primar...

Page 314: ...k Clutch plate Damage Replace the clutch plates as a set 2 Measure Clutch plate warpage with a surface plate and thickness gauge 1 Out of specification Replace the clutch plates as a set EAS25130 CHEC...

Page 315: ...ING THE CLUTCH PUSH RODS 1 Check O ring Short clutch push rod Long clutch push rod Ball Cracks damage wear Replace the defec tive part s 2 Measure Long clutch push rod bending limit Out of specificati...

Page 316: ...ven gear 3 NOTE Make sure that the punch marks a on the left balancer driven gear are facing toward left bal ancer weight 2 2 Remove Generator rotor Refer to REMOVING THE GENERATOR on page 5 79 3 Alig...

Page 317: ...ghten the left balancer drive gear bolt EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Washer Straight key Primary drive gear Crankshaft position sensor rotor 1 Spacer Primary drive gear bolt 2...

Page 318: ...l spring washer mating surfaces with engine oil Install the conical spring washer 2 with the OUT mark a facing out While holding the clutch boss with the univer sal clutch holder 4 tighten the clutch...

Page 319: ...1 Remove Clutch hose union bolt 1 Copper washers 2 Clutch hose 3 NOTE To collect any remaining clutch fluid place a container under the master cylinder and the end of the clutch hose ET1D71037 CHECKI...

Page 320: ...ch hose routing is essential to in sure safe vehicle operation Refer to CABLE ROUTING for XV19S C XV19M C XV19CTS C XV19CTM C on page 2 51 and CABLE ROUTING for XV19CS C XV19C C on page 2 67 NOTE Inst...

Page 321: ...CLUTCH SYSTEM on page 3 15 5 Check Clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL on page 3 14 6 Check...

Page 322: ...id WARNING EWA13370 Use only the designated clutch fluid Other clutch fluids may cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of clutch f...

Page 323: ...CLUTCH 5 74 5 Check Clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM on page 3 15...

Page 324: ...ousing Refer to CLUTCH on page 5 53 1 Washer 3 2 Circlip 2 3 Shift shaft 1 4 Shift shaft spring 1 5 Stopper lever 1 6 Collar 1 7 Stopper lever spring 1 8 Shift shaft spring stopper 1 For installation...

Page 325: ...r Replace EAS25450 INSTALLING THE SHIFT SHAFT 1 Install Stopper lever 1 Collar Stopper lever bolt 2 Stopper lever spring 3 NOTE Hook the ends of the stopper lever spring onto the stopper lever and the...

Page 326: ...page 4 90 Clutch pipe Refer to CLUTCH on page 5 53 1 Stator coil coupler 1 Disconnect 2 Oil delivery pipe 2 1 3 Generator cover 1 4 Generator cover gasket 1 5 Dowel pin 2 6 Stator coil lead holder 1 7...

Page 327: ...utch idle gear shaft 1 3 Starter clutch idle gear 1 4 Generator rotor 1 5 Starter clutch 1 6 Woodruff key 1 7 Starter clutch gear 1 8 Bearing 1 9 Bearing housing 1 For installation reverse the removal...

Page 328: ...r Burrs chips roughness wear Replace the defective part s 3 Check Starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear 4 Check Starter clutch operation a Insta...

Page 329: ...e generator rotor hub When installing the rotor make sure the woo druff key is properly seated in the key way of the generator shaft Lubricate the generator rotor bolt threads and washer mating surfac...

Page 330: ...GENERATOR AND STARTER CLUTCH 5 81...

Page 331: ...AS24780 ELECTRIC STARTER Removing the starter motor Order Job Parts to remove Q ty Remarks 1 Starter motor lead 1 Disconnect 2 Starter motor 1 For installation reverse the removal proce dure 2 1 T R 1...

Page 332: ...ring 1 3 Oil seal 1 4 Circlip 1 5 Starter motor rear cover 1 6 Brush 2 7 Brush holder along with the brushes 1 8 Brush seat along with the brushes 1 9 Bearing 1 10 Gasket 2 11 Armature assembly 1 12 S...

Page 333: ...commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the sta...

Page 334: ...e 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 in the starter motor yoke 2 Install Starter motor front co...

Page 335: ...linder Refer to CLUTCH on page 5 53 Drive pulley Refer to BELT DRIVE on page 4 90 1 Oil pipe 2 1 2 Oil pipe 4 1 3 Transfer gear case cover 1 4 Transfer gear case gasket 1 5 Dowel pin 2 6 Transfer gear...

Page 336: ...ven shaft Order Job Parts to remove Q ty Remarks 8 6 7 1 2 3 12 10 5 5 4 9 7 5 13 New New 7 E New New New New New New 11 LS LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 140 Nm 14 0...

Page 337: ...marks 1 Transfer gear oil pump cover 1 2 Transfer gear oil pump outer rotor 1 3 Transfer gear oil pump inner rotor 1 4 Pin 1 5 Washer 1 6 Transfer gear oil pump shaft 1 7 Transfer gear oil pump housin...

Page 338: ...NK on page 6 1 1 Oil tank breather hose 1 Disconnect 2 Speed sensor 1 3 Oil tank damper 1 4 Dipstick 1 5 Dipstick joint 1 6 Drive pulley case 1 7 Dowel pin 2 8 Spacer 1 9 Transfer gear case 1 10 Dowel...

Page 339: ...cover 1 3 Oil tank cover gasket 1 4 Dowel pin 2 5 Oil strainer 1 6 Oil pipe 5 1 7 Oil tank 1 For assembly reverse the disassembly pro cedure 3 2 15 4 5 6 1 7 New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 28 N...

Page 340: ...age wear Replace the middle drive gear middle driven shaft and primary chain as a set 2 Check Primary chain Damage stiffness Replace the primary chain middle drive gear and middle driven shaft as a se...

Page 341: ...Check Transfer gear oil pump operation Refer to CHECKING THE TRANSFER GEAR OIL PUMP on page 5 91 EAS25530 INSTALLING THE TRANSFER GEAR CASE 1 Install Spacer 1 NOTE Install the spacer with its groove...

Page 342: ...o the middle driven shaft 3 Install Conical spring washer 1 Middle drive gear nut 2 NOTE Lubricate the middle drive gear nut threads and conical spring washer mating surfaces with engine oil Install t...

Page 343: ...n page 5 77 1 Neutral switch 1 2 Oil pipe 3 1 3 Oil strainer 2 4 Oil delivery pipe 3 1 5 Engine oil pump driven gear stopper 1 6 Engine oil pump driven gear 1 7 Oil baffle plate left crankcase 1 8 Lef...

Page 344: ...ove Q ty Remarks New 1 11 9 4 5 6 2 5 7 3 13 8 9 10 12 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T...

Page 345: ...Refer to CRANKSHAFT on page 5 106 Transmission Refer to TRANSMISSION on page 5 112 1 Oil baffle plate right crankcase 1 2 Bearing retainer 2 3 Bearing retainer 2 4 Oil seal 2 5 Bearing 4 For installat...

Page 346: ...E CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check Crankcase Cracks damage Replace Oil delivery passa...

Page 347: ...rankcase onto the right crankcase NOTE Tap lightly on the left crankcase with a soft face hammer 4 Install Crankcase bolts M6 Crankcase bolts M8 NOTE Lubricate the bolt threads with engine oil Tighten...

Page 348: ...oil onto the crankshaft pin bearings and oil de livery holes 6 Check Crankshaft and transmission operation Rough movement Repair A Right crankcase B Left crankcase 4 1 5 3 6 7 2 8 A 21 20 16 15 14 19...

Page 349: ...0 OIL PUMP Removing the oil pump Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 94 1 Oil pump assembly 1 For installation reverse the removal proce dure 1 T R 2...

Page 350: ...1 1 6 Oil strainer 1 7 Pin 2 8 Ball spring 1 9 Oil scavenging pump outer rotor 2 1 10 Oil scavenging pump inner rotor 2 1 11 Pin 1 12 Oil pump housing cover 2 1 13 Relief valve spring 1 14 Relief valv...

Page 351: ...Ball guide 1 24 Oil pump housing 2 1 For assembly reverse the disassembly pro cedure Disassembling the oil pump Order Job Parts to remove Q ty Remarks E E T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg...

Page 352: ...alve spring Damage wear Replace the defective part s ET1D71035 CHECKING THE BALL SPRING AND RELIEF VALVE SPRING 1 Measure Ball spring free length Relief valve spring free length Out of specification R...

Page 353: ...scavenging pump inner rotor 2 15 Oil scavenging pump outer rotor 2 16 Ball spring 17 Pins 18 Oil strainer 19 Oil pump housing 1 20 Pin 21 Oil scavenging pump inner rotor 1 22 Oil scavenging pump outer...

Page 354: ...03 EAS25020 INSTALLING THE OIL PUMP 1 Install Oil pump assembly 1 CAUTION ECA13890 After tightening the bolts make sure the oil pump turns smoothly T R Oil pump assembly bolt 24 Nm 2 4 m kg 17 ft lb E...

Page 355: ...er Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 94 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end...

Page 356: ...e the big end bearings The following procedure applies to all of the connecting rods CAUTION ECA13930 Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin t...

Page 357: ...re f Tighten the connecting rod bolts to the spec ified torque g Put a mark 1 on the connecting rod bolts 2 and the connecting rod cap 3 h Tighten the connecting rod bolts further to reach the specifi...

Page 358: ...5 Measure Crankshaft journal diameter a Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft journal at two places 6 Measure Crankshaft journal bearing inside dia...

Page 359: ...jection c on the connecting rods face towards the left side of the crank shaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten Connecting rod bolts...

Page 360: ...NSTALLING THE CRANKSHAFT ASSEMBLY 1 Install Generator shaft 1 Crankshaft assembly 2 CAUTION ECA13970 To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal li...

Page 361: ...Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 94 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork 1 2 4 Shift fork 2 1 5 Drive axle assembly 1 6 Main a...

Page 362: ...d pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 5th pinion gear 1 5 Collar 1 6 Toothed washer 1 7 Circlip 1 8 3rd pinion gear 1 9 Circlip 1 10 Toothed washer 1 11 4th pinion...

Page 363: ...y Remarks 1 Circlip 1 2 Washer 1 3 1st wheel gear 1 4 Collar 1 5 4th wheel gear 1 6 Circlip 1 7 Toothed washer 1 8 3rd wheel gear 1 9 Collar 1 10 Toothed lock washer 1 11 Toothed lock washer retainer...

Page 364: ...TRANSMISSION 5 115 17 Drive axle 1 For assembly reverse the disassembly pro cedure Disassembling the drive axle assembly Order Job Parts to remove Q ty Remarks...

Page 365: ...lace the shift forks and shift fork guide bar as a set EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment 1 Da...

Page 366: ...p sharp edged corner a is positioned opposite side to the toothed washer and gear for main axle Install the circlip so that both ends b rest on the sides of a spline c with both axles aligned 2 Instal...

Page 367: ...hould 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...

Page 368: ...TRANSMISSION 5 119...

Page 369: ...ROTTLE BODIES 6 7 REMOVING THE FUEL HOSE 6 15 CHECKING THE INJECTORS 6 15 CHECKING THE THROTTLE BODIES 6 15 CHECKING THE ROLLOVER VALVES 6 15 CHECKING THE PRESSURE REGULATOR 6 15 CHECKING THE PRESSURE...

Page 370: ...er assembly coupler 2 Disconnect For XV19CS C XV19C C 4 Fuel sender coupler 1 Disconnect 5 Fuel tank breather hose 1 Disconnect 6 Air vent hose fuel pump to fuel hose joint 1 Disconnect 7 Fuel tank 1...

Page 371: ...nstallation reverse the removal proce dure Removing the fuel tank Order Job Parts to remove Q ty Remarks 1 7 2 9 4 6 10 8 T R 4 Nm 0 4 m kg 2 9 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 7 Nm 0 7 m kg 5 1...

Page 372: ...p coupler 1 Disconnect 2 Fuel hose connector cover 1 3 Fuel outlet hose 1 Disconnect 4 Air vent hose fuel pump to fuel hose joint 1 5 Fuel return hose fuel return pipe to sub fuel tank 1 Disconnect 6...

Page 373: ...nt in the areas shown in the illustration c Turn the screws 1 clockwise NOTE Turn the screws until they stop d Disconnect the fuel hose fuel hose joint to fuel pump 1 and air vent hose fuel pump to fu...

Page 374: ...PUMP 1 Install Fuel pump NOTE Do not damage the installation surfaces of the sub fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustr...

Page 375: ...hose joint caps NOTE Install the fuel hose joint caps completely onto the fuel hose joints 2 Install for XV19S C XV19M C XV19CTS C XV19CTM C Meter assembly couplers Fuel sender coupler NOTE Make sure...

Page 376: ...her hose 1 4 Canister purge hose 1 For California only 5 Rollover valve 1 1 6 Rollover valve 2 1 7 Rollover valve hose 4 8 Fuel tank breather overflow hose 1 For California only 9 Fuel tank breather o...

Page 377: ...Refer to GENERAL CHASSIS on page 4 1 1 Pressure regulator cover 1 2 Fuel tank breather hose 1 3 Rollover valve 1 1 4 Rollover valve 2 1 5 Rollover valve hose 5 6 Fuel tank breather overflow pipe 1 7...

Page 378: ...Disconnect 2 Horn 1 1 3 Pressure regulator cover 1 4 Fuel tank breather hose 1 5 Canister purge hose 1 6 Rollover valve 1 1 7 Rollover valve 2 1 8 Rollover valve hose 4 9 Fuel tank breather overflow...

Page 379: ...e manifold assembly to pres sure regulator 1 3 Air filter case breather hose 1 1 4 Air filter case breather hose 2 1 5 Hose clamp 1 6 Pressure regulator 1 7 Fuel return hose 1 8 Fuel return pipe 1 9 P...

Page 380: ...ignition coil 1 4 Fuel return pipe 1 5 Fuel hose intake manifold assembly to pres sure regulator 1 Disconnect 6 Pressure regulator bracket 1 7 Air filter case breather hose 1 1 8 Air filter case brea...

Page 381: ...on page 5 1 1 Throttle position sensor coupler 1 Disconnect 2 Cylinder 1 intake air pressure sensor hose 1 3 Cylinder 2 intake air pressure sensor hose 1 4 Canister purge hose 1 For California only 5...

Page 382: ...let hose 1 Disconnect 4 Fuel hose intake manifold assembly to pres sure regulator 1 5 Cylinder 2 ISC idle speed control unit outlet hose 1 Disconnect 6 Cylinder 1 ISC idle speed control unit outlet ho...

Page 383: ...1 Disconnect 2 Cylinder 2 injector coupler 1 Disconnect 3 Sub wire harness 2 1 4 Fuel pipe 1 5 Injector joint 1 1 6 Injector joint 2 1 7 Injector 2 For assembly reverse the disassembly pro cedure 5 7...

Page 384: ...ies as a set 2 Check Fuel passages Obstructions Clean a Wash the throttle bodies in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages with co...

Page 385: ...ON d Measure the throttle position sensor output voltage e Adjust the throttle position sensor angle so that the output voltage is within the specified range f After adjusting the throttle position s...

Page 386: ...securely connected and that the fuel hose connector cover on the fuel hose is in the correct position otherwise the fuel hose will not be properly installed NOTE Install the fuel hose securely onto th...

Page 387: ...2 4 Cylinder 1 ISC idle speed control unit outlet hose 2 5 ISC idle speed control unit inlet hose 1 6 Cylinder 2 left ignition coil 1 For XV19S C XV19M C XV19CTS C XV19CTM C 7 Cylinder 2 right igniti...

Page 388: ...ISC IDLE SPEED CONTROL UNIT 6 19 ET1D71010 CHECKING THE ISC IDLE SPEED CONTROL SYSTEM 1 Check Hoses Loose connections Connect properly Cracks damage Replace...

Page 389: ...RGING SYSTEM 7 13 CIRCUIT DIAGRAM 7 13 TROUBLESHOOTING 7 15 LIGHTING SYSTEM 7 17 CIRCUIT DIAGRAM 7 17 TROUBLESHOOTING 7 19 SIGNALING SYSTEM 7 21 CIRCUIT DIAGRAM 7 21 TROUBLESHOOTING 7 23 FUEL INJECTIO...

Page 390: ...TION SENSOR 7 84 CHECKING THE LEAN ANGLE SENSOR 7 85 CHECKING THE STARTER MOTOR OPERATION 7 85 CHECKING THE STATOR COIL 7 85 CHECKING THE RECTIFIER REGULATOR 7 86 CHECKING THE HORNS 7 86 CHECKING THE...

Page 391: ......

Page 392: ...G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G...

Page 393: ...nkshaft position sensor 23 Lean angle sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinder 2 right igni...

Page 394: ...lugs from producing a spark However the engine continues to run under the following conditions The transmission is in gear the neutral switch circuit is open and the sidestand is up the sidestand swit...

Page 395: ...C Refer to CHECKING THE FUS ES on page 7 75 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3...

Page 396: ...aulty Replace the right handlebar switch 10 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the neutral switch 11 Check the sidestand switch Refer to CHECKING THE SWITCHES...

Page 397: ...IGNITION SYSTEM 7 6...

Page 398: ...R G P L W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy...

Page 399: ...XV19M C XV19CTS C XV19CTM C 11 Relay unit 12 Starting circuit cut off relay 14 Neutral switch 15 Diode 2 for XV19S C XV19M C XV19CTS C XV19CTM C 16 Sidestand switch 27 ECU electronic control unit 54 C...

Page 400: ...lled to the handlebar the clutch switch circuit is closed and the sidestand is up the sidestand switch circuit is closed The starting circuit cut off relay prevents the starter motor from operating wh...

Page 401: ...nition fuse 5 Engine stop switch 6 Diode 2 for XV19S C XV19M C XV19CTS C XV19CTM C 7 Relay unit starting circuit cut off relay 8 Relay unit diode 9 Clutch switch 10 Sidestand switch 11 Neutral switch...

Page 402: ...als Recharge or replace the battery 3 Check the starter motor operation Refer to CHECKING THE START ER MOTOR OPERATION on page 7 85 Starter motor is OK Perform the electric starting system troubleshoo...

Page 403: ...1 The engine stop switch is faulty Replace the right handlebar switch 12 Check the neutral switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the neutral switch 13 Check the sidestand switch R...

Page 404: ...L E Y BLACK L B B L Gy Gy B Gy B L B L L P Y B L L P W P W BLACK B L L P Y BLACK B L L W L B L W Y B L L B L W Y B L Br W BLACK Br B Br Br Br B B B B B Br W B L B G W R L B R L G W B B B L Y G L Br B...

Page 405: ...CHARGING SYSTEM 7 14 1 AC magneto 2 Rectifier regulator 4 Main fuse 6 Battery...

Page 406: ...he battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 7 85 Re...

Page 407: ...CHARGING SYSTEM 7 16...

Page 408: ...Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy G B...

Page 409: ...5 Dimmer switch 59 Front right turn signal position light 60 Front left turn signal position light 64 Headlight high beam 65 Headlight low beam 70 Accessory light switch 71 Accessory light OPTION 72 T...

Page 410: ...t signaling system taillight and ECU for XV19S C XV19M C XV19CTS C XV19CTM C Refer to CHECKING THE FUS ES on page 7 75 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY...

Page 411: ...LIGHTING SYSTEM 7 20 NG OK 8 Check the entire lighting system wiring Refer to CIRCUIT DIAGRAM on page 7 17 Properly connect or repair the lighting sys tem wiring The lighting system circuit is OK...

Page 412: ...W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy...

Page 413: ...turn signal indicator light 46 Right turn signal indicator light 48 Fuel sender fuel tank 49 Horn 1 50 Horn 2 51 Turn signal relay 56 Turn signal switch 57 Horn switch 59 Front right turn signal posit...

Page 414: ...system and ECU for XV19S C XV19M C XV19CTS C XV19CTM C Refer to CHECKING THE FUS ES on page 7 75 Replace the fuse s 2 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 7 76 Clean th...

Page 415: ...the front brake light switch 2 Check the rear brake light switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the rear brake light switch 3 Check the entire signaling system wiring Refer to CI...

Page 416: ...lay unit diode Refer to CHECKING THE DI ODES on page 7 81 Replace the relay unit 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signali...

Page 417: ...the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 7 21 Properly connect or repair the signaling system wiring This circuit is OK 1 Check the speed sensor Refer to CHECKING THE SPEED...

Page 418: ...P L W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G...

Page 419: ...sor 25 Air temperature sensor 26 Engine temperature sensor 27 ECU electronic control unit 28 Cylinder 1 left ignition coil 29 Cylinder 1 right ignition coil 30 Cylinder 2 left ignition coil 31 Cylinde...

Page 420: ...ode has been displayed it remains stored in the memory of the ECU until it is deleted Engine trouble warning light indication and fuel injection system operation The warning light flashes when any one...

Page 421: ...system Cylinder 1 intake air pressure sensor hose system malfunction clogged or detached hose Able Able 15 Throttle position sen sor open or short circuit Throttle position sensor open or short circu...

Page 422: ...coil Able depending on the number of faulty cylin ders Able depending on the number of faulty cylin ders 37 ISC valve stuck fully open Engine speed is high when the en gine is idling Able Able 41 Lea...

Page 423: ...en left idling The ECU automatically stops the en gine after 20 minutes if it is left idling Able Able Fault code No Item Symptom Able un able to start Able un able to drive Fault code No Item Symptom...

Page 424: ...ess the switch for 8 seconds or more NOTE All displays on the meter disappear except the clock and odometer trip meter fuel reserve trip meter clock displays dIAG appears on the odometer trip meter fu...

Page 425: ...nction in ECU Improperly installed sensor 13 Cylinder 1 intake air pres sure sensor open or short circuit detected Open or short circuit in wire harness Defective cylinder 1 intake air pressure sensor...

Page 426: ...ort circuit detected Open or short circuit in wire sub lead Open or short circuit in wire harness Defective engine temperature sensor Malfunction in ECU Improperly installed sensor 11 30 The vehicle h...

Page 427: ...sensor Malfunction in ECU 08 42 No normal signals are re ceived from the speed sen sor Open circuit is detected in the neutral switch Open circuit in wire harness Defective speed sensor Malfunction in...

Page 428: ...n 12 22 Check with throttle fully closed Fully opened position 87 107 Check with throttle fully open 03 Pressure difference atmospheric pressure and cylinder 1 intake air pres sure Displays the cylind...

Page 429: ...r Displays the operating angle Engine trouble warning light comes on twice once when the EXUP valve is closing and once when it is opening 60 EEPROM fault code dis play No history 00 History exists 01...

Page 430: ...the engine trou ble warning light Check the spark five times Connect an ignition checker 33 Cylinder 2 left or right ig nition coil Actuates the cylinder 2 left or right ignition coil five times at on...

Page 431: ...ction table Diagnostic code No Diagnostic code number to be used when the diagnostic mode is operated Refer to DIAGNOSTIC MODE on page 7 33 52 Headlight relay Actuates the headlight relay for five cyc...

Page 432: ...Crankshaft position sensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it an...

Page 433: ...er for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short ci...

Page 434: ...ing the en gine and oper ating it at idle 2 Cylinder 1 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tio...

Page 435: ...pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely 3 Open or short circuit in wire harness and or sub lead Repair or replace if...

Page 436: ...Replace if defective Refer to CHECKING THE EXUP SERVO MOTOR on page 7 90 Fault code No 18 Symptom EXUP servo motor is stuck Diagnostic code No 53 EXUP servo motor Order Item components and probable ca...

Page 437: ...lace if defective Refer to CHECKING THE SWITCHES on page 7 71 Fault code No 22 Symptom Air temperature sensor open or short circuit detected Diagnostic code No 05 Air temperature sensor Order Item com...

Page 438: ...ensor coupler Main wire harness ECU coupler Check the coupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler...

Page 439: ...oupler for any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or shor...

Page 440: ...ing the en gine and oper ating it at idle 2 Cylinder 2 intake air pressure sensor malfunction at intermediate electrical potential Check and repair the connec tion Replace it if there is a malfunc tio...

Page 441: ...er brown brown black black 4 Defective engine temperature sensor Execute the diagnostic mode Code No 11 Replace if defective Refer to CHECKING THE EN GINE TEMPERATURE SEN SOR on page 7 87 Fault code N...

Page 442: ...pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idl...

Page 443: ...any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at...

Page 444: ...pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at idl...

Page 445: ...any pins that may be pulled out Check the locking condition of the connector and coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and oper ating it at...

Page 446: ...to ADJUSTING THE THROTTLE CABLE FREE PLAY on page 3 8 3 ISC valve is stuck fully open due to disconnected ISC unit hose or cou pler High engine idle speed is de tected with the ISC valve stuck fully o...

Page 447: ...any pins that may be pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect the coupler se curely Turning the main switch to ON 2 Open or short circuit...

Page 448: ...dition of the coupler If there is a malfunction repair it and connect the coupler se curely Starting the en gine and acti vating the vehicle speed sensor by oper ating the vehi cle at 20 to 30 km h A...

Page 449: ...d relay unit coupler fuel pump relay sky blue sky blue Between relay unit coupler and main switch blue yellow blue yellow Between main switch and ECU coupler blue black blue black B 3 Faulty shift dru...

Page 450: ...ler fuel pump relay and battery termi nal red red Between relay unit coupler fuel pump relay and diode 2 cou pler for XV19S C XV19M C XV19CTS C XV19CTM C red white red white Between diode 2 coupler an...

Page 451: ...7 76 3 Malfunction in rectifier regulator Replace if defective Refer to CHARGING SYS TEM on page 7 13 4 Open or short circuit in wire harness Repair or replace if there is an open or short circuit Bet...

Page 452: ...ue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 2 Symptom No signals are received from the ECU within the specified duration Diagnos...

Page 453: ...ue yellow blue 3 Malfunction in meter assembly Replace the meter assembly 4 Malfunction in ECU Replace the ECU Fault code No Er 4 Symptom Non registered data has been received from the meter Diagnosti...

Page 454: ...W G Br L Gy R Gy R Gy R Gy R R G P L W G Br L R G P L W G Br L R G R B R B R B R B R B R B D D C C D D Y B Gy W W R B G B R W R BLACK L W R B G B R B L L B G B R B L W G GRAY W Gy DARK GRAY Gy G G Gy...

Page 455: ...tery 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...

Page 456: ...G THE BATTERY on page 7 76 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 7 71 Replace the main switch 4 Check the engine st...

Page 457: ...FUEL PUMP SYSTEM 7 66 NG OK 8 Check the entire fuel pump system wiring Refer to CIRCUIT DIAGRAM on page 7 63 Properly connect or repair the fuel pump system wiring Replace the ECU...

Page 458: ...ELECTRICAL COMPONENTS 7 67 EAS27970 ELECTRICAL COMPONENTS 13 3 6 9 10 12 4 11 14 15 5 2 1 7 8 16...

Page 459: ...C XV19CTS C XV19CTM C Cylinder 2 right ignition coil for XV19CS C XV19C C 6 Cylinder 1 right ignition coil for XV19S C XV19M C XV19CTS C XV19CTM C Cylinder 1 right ignition coil for XV19CS C XV19C C...

Page 460: ...ELECTRICAL COMPONENTS 7 69 16 18 2 11 13 9 8 10 12 14 15 17 1 3 4 5 6 7...

Page 461: ...ntake air pressure sensor 6 Fuse box 7 Starter relay 8 Fuel injection system fuse 9 Battery 10 Diode 2 for XV19S C XV19M C XV19CTS C XV19CTM C 11 Turn signal relay 12 Headlight relay 13 Relay unit 14...

Page 462: ...3 10 6 12 9 Y G L G B P Br Y R W B R L W W B R Br R Br L Y L B ON OFF G Y G B PUSH Ch Br W Dg B Y R L R GRAY Dg Ch GRAY B B G YG B BLUE Y G G L GRAY B P Y R Br W L Y B Y B B BLACK B B BLACK 8 7 BLUE B...

Page 463: ...h 2 Engine stop switch 3 Start switch 4 Accessory light switch 5 Front brake light switch 6 Neutral switch 7 Sidestand switch 8 Rear brake light switch 9 Clutch switch 10 Horn switch 11 Dimmer switch...

Page 464: ...er to 0 and to the 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following e...

Page 465: ...ition of the bulbs The following procedure applies to all of the bulbs 1 Remove Bulb WARNING EW1D71009 Since headlight bulbs get extremely hot keep flammable products and your hands away from them unt...

Page 466: ...cking or replacing a fuse 1 Remove Rider seat Refer to GENERAL CHASSIS on page 4 1 2 Check Fuse a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to...

Page 467: ...15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion CAUTION EC...

Page 468: ...tage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example 7 Charge Battery refer to the appropriate charging method il lustration Positive tester...

Page 469: ...r and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery stabi lizes about 30 minutes after chargin...

Page 470: ...e battery unused for more than 30 minutes 8 Install Battery 9 Connect Battery leads to the battery terminals CAUTION ECA13630 First connect the positive battery lead 1 and then the negative battery le...

Page 471: ...e 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1...

Page 472: ...re the turn signal relay output voltage EAS28050 CHECKING THE DIODES Relay unit diode 1 Check Relay unit diode Out of specification Replace NOTE The pocket tester or the analog pocket tester readings...

Page 473: ...ster probe sky blue 1 Negative tester probe black yellow 2 No continuity Positive tester probe black yellow 2 Negative tester probe sky blue 1 Continuity Positive tester probe sky blue 1 Negative test...

Page 474: ...the main switch to ON and engine stop switch to d Measure the ignition spark gap a e Crank the engine by pushing the start switch and gradually increase the spark gap un til a misfire occurs EAS28070...

Page 475: ...ure the secondary coil resistance EAS28120 CHECKING THE CRANKSHAFT POSITION SENSOR 1 Disconnect Crankshaft position sensor coupler from the wire harness 2 Check Crankshaft position sensor resistance O...

Page 476: ...ith step 5 Refer to TROUBLESHOOTING on page 7 11 a Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 WARNING EWA13810 A wire that is used as a jumper lead must have...

Page 477: ...ING THE HORNS 1 Check Horn resistance Out of specification Replace a Disconnect the horn 1 connectors and horn 2 coupler from the horn terminals b Connect the pocket tester 1 to the horn terminals Sta...

Page 478: ...d WARNING EWA14140 Handle the engine temperature sensor with special care Never subject the engine temperature sen sor to strong shocks If the engine temper ature sensor is dropped replace it 2 Check...

Page 479: ...to maximum 3 minimum 4 level position c Measure the fuel sender resistance ET1D71015 CHECKING THE FUEL SENDER FUEL PUMP 1 Drain the fuel 2 Disconnect Fuel pump coupler from the fuel pump 3 Remove Fuel...

Page 480: ...upler as shown b Turn the main switch to ON c Elevate the rear wheel and slowly rotate it d Measure the voltage of white and black With each full rotation of the rear wheel the volt age reading should...

Page 481: ...pump coupler from the fuel pump 2 Check Fuel pump operation Faulty rough movement Replace a Fill the fuel tank b Put the end of the fuel hose 1 into an open container c Connect the battery DC 12 V to...

Page 482: ...the air temperature sensor to strong shocks If the air temperature sen sor is dropped replace it 2 Check Air temperature sensor resistance Out of specification Replace a Connect the pocket tester 100...

Page 483: ...NGINE 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 PERFORMANC...

Page 484: ...riorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty relay unit fuel pump relay 3 Throttle body ies Deteriorated or contaminated fuel Sucked in air Electrical system 1 Battery Discharged...

Page 485: ...e Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft I...

Page 486: ...rod assembly bolt Damaged damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Malfunction Bent or damaged inner tube Bent or damaged outer tube Damaged fork spring Worn or damage...

Page 487: ...ight LED Faulty battery Incorrectly adjusted rear brake light switch Tail brake light LED life expired Turn signal does not come on Faulty turn signal switch Faulty turn signal relay Burnt out turn si...

Page 488: ...y 52 Headlight relay 53 Left handlebar switch 54 Clutch switch 55 Dimmer switch 56 Turn signal switch 57 Horn switch 58 Select switch 59 Front right turn signal position light 60 Front left turn signa...

Page 489: ...light relay 50 Left handlebar switch 51 Clutch switch 52 Dimmer switch 53 Turn signal switch 54 Horn switch 55 Select switch 56 Front right turn signal position light 57 Front left turn signal positio...

Page 490: ......

Page 491: ......

Page 492: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

Page 493: ...Y GRAY WIRE HARNESS WIRE HARNESS WIRE HARNESS SUB WIRE HARNESS2 E WIRE HARNESS SUB WIRE HARNESS2 SUB WIRE HARNESS4 SUB WIRE HARNESS3 B C D BLACK BLACK BLACK BLACK ON OFF D D C C D D C D D E E E B B B...

Page 494: ...UB WIRE HARNESS2 C WIRE HARNESS SUB WIRE HARNESS1 SUB WIRE HARNESS2 A B RED RED GRAY GRAY YELLOW BLACK BLACK GREEN GREEN YELLOW BLACK L N R PUSH C BLACK GRAY B B B B BLACK BLACK BLACK GRAY DARK GRAY A...

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