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Yamaha STAR XV19CSX(C) Service Manual

Other manuals for STAR XV19CSX(C): Owner's Manual

Summary of STAR XV19CSX(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

    Eas20050 xv19sx(c)/xv19mx(c)/xv19ctsx(c)/ xv19ctmx(c)/xv19csx(c)/xv19cx(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.S.A. Is expressly prohi...

  • Page 3

    Eas20070 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on yama...

  • Page 4

    Eas20090 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. • the manual is di...

  • Page 5

    Eas20100 symbols the following symbols are used in this manual for easier understanding. Note: the following symbols are not relevant to every vehicle. G m e b ls m 9 10 11 12 13 14 15 16 17 18 lt new bf s t r . . 1 2 3 4 5 6 7 8 1. Serviceable with engine mounted 2. Filling fluid 3. Lubricant 4. Sp...

  • Page 7: Table of Contents

    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 9: General Information

    1 general information identification ............................................................................................ 1-1 vehicle identification number ..................................................... 1-1 model label......................................................................

  • Page 10: Identification

    Identification 1-1 eas20130 identification eas20140 vehicle identification number the vehicle identification number “1” is stamped into the right side of the steering head pipe. Eas20150 model label the model label “1” is affixed to the frame under the rider seat. This information will be needed to ...

  • Page 11: Features

    Features 1-2 eas20170 features et1d71017 outline of the fi system the main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor sy...

  • Page 12: Features

    Features 1-3 et1d71018 fi system the fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kpa (3.92 kg/cm², 55.7 psi). Accordingly, when the energizing signal from the ecu energizes the f...

  • Page 13: Features

    Features 1-4 et1d71036 instrument functions (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) multi-function meter unit warning ew1d71008 be sure to stop the vehicle before making any setting changes to the multi-function meter unit. The multi-function meter unit is equipped with the following: • a s...

  • Page 14: Features

    Features 1-5 tachometer the electric tachometer allows the rider to mon- itor the engine speed and keep it within the ideal power range. When the key is turned to “on”, the tachometer needle will sweep once across the r/min range and then return to zero r/min in order to test the electrical circuit....

  • Page 15: Features

    Features 1-6 to set the clock: 1. Push the “select” switch to change the dis- play to the clock mode. 2. Push the “select” and “reset” switches together for at least two seconds. 3. When the hour digits start flashing, push the “reset” switch to set the hours. 4. Push the “select” switch, and the mi...

  • Page 16: Features

    Features 1-7 7. Push the “select” switch. The odometer/tripmeter/clock display will re- turn to the prior mode. Eas1d77010 instrument functions (for xv19cs(c)/ xv19c(c)) multi-function meter unit warning ewa1d77001 be sure to stop the vehicle before making any setting changes to the multi-function m...

  • Page 17: Features

    Features 1-8 fuel gauge the fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “e” (empty) as the fuel level decreases. When the needle reaches “e”, approximately 3.0 l (0.79 us gal) (0.66 imp.Gal) remain in the fuel tank. If this occurs, refuel as soon as possible. W...

  • Page 18: Features

    Features 1-9 odometer, tripmeters, fuel reserve tripmeter and clock push the “select” switch to change the display between the odometer mode “odo”, the tripme- ter modes “trip a” and “trip b” in the following order: odo → trip a → trip b → odo if the fuel level warning light comes on, the odometer d...

  • Page 19: Features

    Features 1-10 to set the brightness 1. Turn the key to “off”. 2. Push and hold the “select” switch. 3. Turn the key to “on”, and then release the “select” switch after five seconds. 4. Adjust the multi-function meter unit panel brightness level by pushing the reset switch. 5. Push the “select” switc...

  • Page 20: Important Information

    Important information 1-11 eas20180 important information eas20190 preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equip- ment. Refer to “special tools” on page 1-14. 3. When disasse...

  • Page 21: Important Information

    Important information 1-12 eas20230 bearings and oil seals install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if a...

  • Page 22: Checking The Connections

    Checking the connections 1-13 eas20250 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector moisture → dry with an air blower. Rust/stains → connect and disconnect sev- e...

  • Page 23: Special Tools

    Special tools 1-14 eas20260 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers o...

  • Page 24: Special Tools

    Special tools 1-15 timing light 90890-03141 inductive clamp timing light yu-03141 3-10 oil filter wrench 90890-01426 yu-38411 3-12 belt tension gauge 90890-03170 rear drive belt tension gauge ym-03170 3-26 steering nut wrench 90890-01403 spanner wrench yu-33975 3-27, 4-81 damper rod holder 90890-014...

  • Page 25: Special Tools

    Special tools 1-16 valve guide remover (ø6) 90890-04064 valve guide remover (6.0 mm) ym-04064-a 5-43 valve guide installer (ø6) 90890-04065 valve guide installer (6.0 mm) ym-04065-a 5-43 valve guide reamer (ø6) 90890-04066 valve guide reamer (6.0 mm) ym-04066 5-43 piston pin puller set 90890-01304 p...

  • Page 26: Special Tools

    Special tools 1-17 yamaha bond no. 1215 90890-85505 (three bond no.1215®) 5-70, 5-80, 5-98 rotor puller 90890-01080 stator rotor puller ym-01080-a 5-79 vacuum/pressure pump gauge set 90890-06756 mityvac brake bleeding tool ys-42423 6-16 pressure gauge 90890-03153 yu-03153 6-16 fuel pressure adapter ...

  • Page 27: Specifications

    2 specifications general specifications ........................................................................ 2-1 engine specifications ............................................................................ 2-3 chassis specifications ............................................................

  • Page 28: General Specifications

    General specifications 2-1 eas20280 general specifications model model xv19sx 1d77 (usa) xv19sxc 1d78 (california) xv19sx 1d79 (cdn) xv19mx 4d57 (usa) xv19mxc 4d58 (california) xv19mx 4d59 (cdn) xv19ctsx 2c57 (usa) xv19ctsxc 2c58 (california) xv19ctsx 2c59 (cdn) xv19ctmx 4p17 (usa) xv19ctmxc 4p18 (c...

  • Page 29: General Specifications

    General specifications 2-2 ground clearance xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 155 mm (6.10 in) xv19cs(c)/ xv19c(c): 146 mm (5.75 in) minimum 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(...

  • Page 30: Engine Specifications

    Engine specifications 2-3 eas20290 engine specifications engine engine type air cooled 4-stroke, ohv displacement 1854.0 cm³ cylinder arrangement v-type 2-cylinder bore × stroke 100.0 × 118.0 mm (3.94 × 4.65 in) compression ratio 9.48 :1 starting system electric starter fuel recommended fuel premium...

  • Page 31: Engine Specifications

    Engine specifications 2-4 oil-pump-housing-to-inner-and-outer-rotor clearance 0.06–0.13 mm (0.0024–0.0051 in) limit 0.20 mm (0.0079 in) bypass valve opening pressure 80.0–120.0 kpa (11.6–17.4 psi) (0.80–1.20 kgf/cm²) relief valve operating pressure 600.0 kpa (87.0 psi) (6.00 kgf/cm²) transfer gear o...

  • Page 32: Engine Specifications

    Engine specifications 2-5 limit 35.850 mm (1.4114 in) rocker arm/rocker arm shaft rocker arm inside diameter 18.000–18.018 mm (0.7087–0.7094 in) limit 18.036 mm (0.7101 in) rocker arm shaft outside diameter 17.976–17.991 mm (0.7077–0.7083 in) rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (...

  • Page 33: Engine Specifications

    Engine specifications 2-6 limit 6.050 mm (0.2382 in) valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) limit 0.080 mm (0.0032 in) valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) limit 0.100 mm (0.0039 in) valve stem runout 0.010 mm (0.0004...

  • Page 34: Engine Specifications

    Engine specifications 2-7 cylinder bore 100.000–100.010 mm (3.9370–3.9374 in) taper limit 0.050 mm (0.0020 in) out of round limit 0.050 mm (0.0020 in) piston piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in) limit 0.15 mm (0.0059 in) diameter d 99.960–99.975 mm (3.9354–3.9360 in) height...

  • Page 35: Engine Specifications

    Engine specifications 2-8 oil ring dimensions (b × t) 2.50 × 3.40 mm (0.10 × 0.13 in) end gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) connecting rod oil clearance (using plastigauge®) 0.050–0.074 mm (0.0020–0.0029 in) bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow crankshaft width a ...

  • Page 36: Engine Specifications

    Engine specifications 2-9 secondary reduction system belt drive secondary reduction ratio xv19sx(c)/ xv19mx(c)/ xv19ctsx(c)/ xv19ctmx(c): 70/31 (2.258) xv19cs(c)/ xv19c(c): 66/31 (2.129) operation left foot operation gear ratio 1st 38/16 (2.375) 2nd 33/21 (1.571) 3rd 29/25 (1.160) 4th 26/28 (0.929) ...

  • Page 37: Engine Specifications

    Engine specifications 2-10 throttle position sensor resistance xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 4.0–6.0 k Ω/blue-black xv19cs(c)/ xv19c(c): 3.1–5.7 k Ω/blue-black output voltage (at idle) 0.63–0.73 v fuel injection sensor crankshaft position sensor resistance 248–372 Ω intake air pressure...

  • Page 38: Chassis Specifications

    Chassis specifications 2-11 eas20300 chassis specifications chassis frame type double cradle caster angle xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 31.30 ° xv19cs(c)/ xv19c(c): 33.20 ° trail xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 152.0 mm (5.98 in) xv19cs(c)/ xv19c(c): 102.0 mm (4.02 in) fron...

  • Page 39: Chassis Specifications

    Chassis specifications 2-12 manufacturer/model xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): dunlop/d251f manufacturer/model xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): bridgestone/g851 radial g manufacturer/model xv19cs(c)/ xv19c(c): metzeler/880 marathon wear limit (front) 1.0 mm (0.04 in) rear tire...

  • Page 40: Chassis Specifications

    Chassis specifications 2-13 limit 0.5 mm (0.02 in) master cylinder inside diameter 14.00 mm (0.55 in) caliper cylinder inside diameter 27.00 mm (1.06 in) caliper cylinder inside diameter 30.23 mm (1.19 in) recommended fluid dot 4 rear brake type single disc brake operation right foot operation brake...

  • Page 41: Chassis Specifications

    Chassis specifications 2-14 installed length xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 268.9 mm (10.59 in) xv19cs(c)/ xv19c(c): 402.0 mm (15.83 in) spring rate k1 xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 10.0 n/mm (57.1 lb/in) (1.02 kgf/mm) xv19cs(c)/ xv19c(c): 8.34 n/mm (47.0 lb/in) (0.84 kgf/...

  • Page 42: Chassis Specifications

    Chassis specifications 2-15 limit xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 176.4 mm (6.94 in) xv19cs(c)/ xv19c(c): 183.3 mm (7.22 in) installed length xv19s(c)/ xv19m(c): 171.0 mm (6.73 in) xv19cts(c)/ xv19ctm(c): 165.0 mm (6.50 in) xv19cs(c)/ xv19c(c): 172 mm (6.77 in) spring rate k1 xv19s(c)/ x...

  • Page 43: Electrical Specifications

    Electrical specifications 2-16 eas20310 electrical specifications voltage system voltage 12 v ignition system ignition system transistorized coil ignition (digital) advancer type electrical ignition timing (b.T.D.C.) 10.0 °/900 r/min engine control unit model/manufacturer xv19s(c)/ xv19m(c)/ xv19cts...

  • Page 44: Electrical Specifications

    Electrical specifications 2-17 high beam headlight xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c): 12 v, 55.0 w × 1 headlight xv19cs(c)/ xv19c(c): 12 v, 60.0 w/55.0 w × 1 tail/brake light led front turn signal/position light 12 v, 23 w/8.0 w × 2 rear turn signal light 12 v, 21.0 w × 2 license plate ligh...

  • Page 45: Electrical Specifications

    Electrical specifications 2-18 turn signal blinking frequency 75.0–95.0 cycles/min wattage 21(23) w × 2 + led × 2 fuel gauge model/manufacturer xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) 1d7/yamaha xv19cs(c)/ xv19c(c): 5c7/nippon seiki sender unit resistance (full) 9–11 Ω sender unit resistance (emp...

  • Page 46: Electrical Specifications

    Electrical specifications 2-19 spare fuse 3.0 a.

  • Page 47: Tightening Torques

    Tightening torques 2-20 eas20320 tightening torques eas20330 general tightening torque specifications this chart specifies tightening torques for stan- dard fasteners with a standard iso thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapt...

  • Page 48: Tightening Torques

    Tightening torques 2-21 eas20340 engine tightening torques item thread size q’ty tightening torque remarks cylinder head nut m12 8 60 nm (6.0 m·kg, 43 ft·lb) cylinder head stud bolt (exhaust pipe) m8 4 15 nm (1.5 m·kg, 11 ft·lb) spark plug m12 4 18 nm (1.8 m·kg, 13 ft·lb) engine temperature sensor —...

  • Page 49: Tightening Torques

    Tightening torques 2-22 oil pipe 4 bolt m6 3 10 nm (1.0 m·kg, 7.2 ft·lb) oil pump housing cover 1 screw (crankcase) m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) oil pump housing cover 2 screw (crankcase) m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) throttle body joint clamp screw m5 2 3 nm (0.3 m·kg, 2.2 ft·lb) pressure regu...

  • Page 50: Tightening Torques

    Tightening torques 2-23 crankshaft position sensor lead holder screw m6 6 10 nm (1.0 m·kg, 7.2 ft·lb) clutch cover damper plate screw m6 4 10 nm (1.0 m·kg, 7.2 ft·lb) camshaft cover bolt m6 8 10 nm (1.0 m·kg, 7.2 ft·lb) generator cover damper bolt m5 3 5 nm (0.5 m·kg, 3.6 ft·lb) engine oil filler pl...

  • Page 51: Tightening Torques

    Tightening torques 2-24 *1 for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) *2 for xv19cs(c)/ xv19c(c) note: • tighten the connecting rod bolts to 15 nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach the specified angle 125–135°. • install the crankcase stud bolts (m12) so that their ins...

  • Page 52: Tightening Torques

    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: Tightening Torques

    Tightening torques 2-26 eas20350 chassis tightening torques item thread size q’ty tightening torque remarks engine mounting bolt (left upper side) m12 2 66 nm (6.6 m·kg, 48 ft·lb) engine mounting bolt (right upper side)*1, 2 m12 2 59 nm (5.9 m·kg, 43 ft·lb) engine mounting bolt (right upper side)*3 ...

  • Page 54: Tightening Torques

    Tightening torques 2-27 horn 2 bolt*3 m6 2 10 nm (1.0 m·kg, 7.2 ft·lb) isc (idle speed control) unit bolt m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) isc (idle speed control) unit bracket bolt m6 4 7 nm (0.7 m·kg, 5.1 ft·lb) pivot shaft nut m18 1 125 nm (12.5 m·kg, 90 ft·lb) relay arm nut (relay arm and swingar...

  • Page 55: Tightening Torques

    Tightening torques 2-28 lower ring nut (final tightening torque) m30 1 18 nm (1.8 m·kg, 13 ft·lb) see note. Hose guide and lower handlebar holder nut*1, 2 m10 2 32 nm (3.2 m·kg, 23 ft·lb) hose guide and lower handlebar holder nut*3 m12 2 40 nm (4.0 m·kg, 29 ft·lb) front brake master cylinder hold- e...

  • Page 56: Tightening Torques

    Tightening torques 2-29 fuel tank and fuel tank bracket bolt (front side) m6 2 7 nm (0.7 m·kg, 5.1 ft·lb) fuel tank and fuel tank bracket bolt (rear side) m6 1 10 nm (1.0 m·kg, 7.2 ft·lb) meter cover bolt m6 3 7 nm (0.7 m·kg, 5.1 ft·lb) fuel pump bolt m5 6 5 nm (0.5 m·kg, 3.6 ft·lb) fuel return pipe...

  • Page 57: Tightening Torques

    Tightening torques 2-30 positive battery lead bolt (starter relay side)*1, 2 m6 1 7 nm (0.7 m·kg, 5.1 ft·lb) starter motor lead bolt (starter relay side)*3 m6 1 5 nm (0.5 m·kg, 3.6 ft·lb) positive battery lead bolt (starter relay side)*3 m6 1 5 nm (0.5 m·kg, 3.6 ft·lb) rear fender bracket and frame ...

  • Page 58: Tightening Torques

    Tightening torques 2-31 locknut (shift rod) m8 2 12 nm (1.2 m·kg, 8.7 ft·lb) shift arm bolt m6 1 12 nm (1.2 m·kg, 8.7 ft·lb) shift pedal bolt (toe side)*1, 2 m6 1 14 nm (1.4 m·kg, 10 ft·lb) shift pedal bolt (heel side)*1, 2 m6 1 13 nm (1.3 m·kg, 9.4 ft·lb) shift pedal bolt*3 m8 1 30 nm (3.0 m·kg, 22...

  • Page 59: Tightening Torques

    Tightening torques 2-32 *1 for xv19s(c)/ xv19m(c) *2 for xv19cts(c)/ xv19ctm(c) *3 for xv19cs(c)/ xv19c(c) note: 1. First, tighten the lower ring nut to 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 ...

  • Page 60

    Lubrication points and lubricant types 2-33 eas20360 lubrication points and lubricant types eas20370 engine lubrication point lubricant oil seal lips o-rings bearings cylinder head nuts and washers connecting rod small end and big end crankshaft journals piston surfaces piston pins connecting rod bo...

  • Page 61

    Lubrication points and lubricant types 2-34 transmission gears (wheel and pinion) and collar drive pulley nut and conical spring washer middle drive gear nut and conical spring washer shift forks and shift fork guide bars shift drum shift shaft and shift shaft oil seal shift fork pawl crankcase mati...

  • Page 62

    Lubrication points and lubricant types 2-35 eas20380 chassis *1 for xv19cs(c)/ xv19c(c) lubrication point lubricant steering bearings and upper bearing dust cover lip lower bearing dust seal lip lower bracket steering shaft*1 steering stem bolt*1 front wheel oil seal lips (left and right) rear wheel...

  • 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

    Lubrication system chart and diagrams 2-38 1. Oil strainer (transfer gear case) 2. Oil pump 3. Oil tank 4. Drive axle 5. Main axle 6. Oil strainer (crankcase) 7. Balancer 8. Front cylinder head cover 9. Rear cylinder head cover 10. Rear cylinder camshaft 11. Front cylinder camshaft 12. Rear valve li...

  • 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

    Lubrication system 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 delivery pipe 3.

  • 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: Xv19Ctm(C))

    Cable routing (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 b c e f g d.

  • Page 79: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-52 1. Clutch hose 2. Right handlebar switch lead 3. Main switch 4. Left handlebar switch lead 5. Front brake hose 6. Throttle cable (decelerator cable) 7. Throttle cable (accelerator cable) 8. Horn 1 lead 9. Horn 1 10. Rear brake light...

  • Page 80: Xv19Ctm(C))

    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: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-54 1. Main switch lead 2. Right handlebar switch lead 3. Wire harness 4. Left handlebar switch lead 5. Air temperature sensor lead 6. Front left turn signal/position light lead 7. Headlight lead 8. Front right turn signal/position ligh...

  • Page 82: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-55 d d e a a 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 ad af u ab aa ac 28 y x...

  • Page 83: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-56 1. Exup servo motor 2. Fuse box 3. Wire harness 4. Fuel outlet hose 5. Cylinder-#1 right spark plug cap 6. Cylinder-#1 right ignition coil 7. Cylinder-#2 intake air pressure sensor coupler 8. Fuel sender (fuel tank) coupler 9. Meter...

  • Page 84: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-57 e 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 25 26 27 28 29 30 31 32 33 36 ...

  • Page 85: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-58 1. Clutch hose 2. Throttle cable (decelerator cable) 3. Throttle cable (accelerator cable) 4. Cylinder-#2 left spark plug cap 5. Cylinder-#1 left spark plug cap 6. Sub-wire harness 1 7. Rectifier/regulator 8. Crankshaft position sen...

  • Page 86: Xv19Ctm(C))

    Cable routing (for xv19s(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 9 e a d b 27 28 v x y j.

  • Page 87: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-60 1. Meter assembly coupler 2. Cylinder-#2 intake air pressure sensor coupler 3. Cylinder-#1 right spark plug cap 4. Wire harness 5. Negative battery lead 6. Exup servo motor 7. Fuse box 8. Starter motor lead 9. Positive battery lead ...

  • Page 88: Xv19Ctm(C))

    Cable routing (for xv19s(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 24 25 28 h f 24 g.

  • Page 89: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-62 1. Fuel tank breather hose 2. Fuel sender (fuel tank) 3. Fuel tank 4. Fuel hose (fuel tank to fuel hose joint) 5. Fuel return hose (fuel return pipe to sub-fuel tank) 6. Air vent hose (fuel hose joint to fuel tank) 7. Fuel hose join...

  • Page 90: Xv19Ctm(C))

    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: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-64 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#1 intake air pressure sensor hose 3. Air filter case breather hose 1 4. Fuel hose (intake manifold assembly to pressure regulator) 5. Pressure regulator 6. Air filter case breat...

  • Page 92: Xv19Ctm(C))

    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: Xv19Ctm(C))

    Cable routing (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2-66 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor hose 3. Cylinder-#2 intake air pressure sensor 4. Isc (idle speed control) unit coupler 5. Isc (idle speed control) unit 6. Rollover valve 1 7. Roll...

  • 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

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-68 1. Clutch hose 2. Left handlebar switch lead 3. Right handlebar switch lead 4. Front brake hose 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Horn 1 lead 8. Horn 1 9. Rear brake light switch lead 10. Rear brake light switc...

  • 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

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-70 1. Front right turn signal/position light lead 2. Wire harness 3. Main switch lead 4. Accessory light coupler 5. Joint coupler 6. Air temperature sensor lead 7. Front left turn signal/position light lead 8. Right handlebar switch lead 9. Main switch 10. L...

  • Page 98

    Cable routing (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 r 8 9.

  • Page 99

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-72 1. Exup servo motor 2. Fuse box 3. Wire harness 4. Fuel outlet hose 5. Cylinder-#1 right spark plug cap 6. Cylinder-#1 right ignition coil 7. Cylinder-#2 intake air pressure sensor coupler 8. Fuel sender (fuel tank) coupler 9. Meter assembly coupler 10. F...

  • Page 100

    Cable routing (for xv19cs(c)/ 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 32 32 b-b 19 30 31 33 a aa.

  • Page 101

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-74 1. Clutch hose 2. Throttle cable (accelerator cable) 3. Throttle cable (decelerator cable) 4. Right handlebar switch coupler 5. Left handlebar switch coupler 6. Cylinder-#1 left ignition coil 7. Cylinder-#1 left spark plug cap 8. Sub-wire harness 1 9. Rec...

  • Page 102

    Cable routing (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 29 30 a c c a b.

  • Page 103

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-76 1. Cylinder-#2 intake air pressure sensor coupler 2. Meter assembly coupler 3. Fuel sender (fuel tank) coupler 4. Cylinder-#1 right spark plug cap 5. Wire harness 6. Negative battery lead 7. Exup servo motor lead 8. Fuse box 9. Starter motor lead 10. Posi...

  • Page 104

    Cable routing (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 19 e f e f.

  • Page 105

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-78 1. Fuel tank breather hose 2. Fuel tank 3. Air vent hose (fuel hose joint to fuel tank) 4. Fuel hose (fuel tank to fuel hose joint) 5. Fuel return hose (fuel return pipe to sub-fuel tank) 6. Fuel hose joint 7. Fuel outlet hose 8. Fuel pump 9. Sub-fuel tan...

  • 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

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-80 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#1 intake air pressure sensor hose 3. Air filter case breather hose 1 4. Fuel hose (intake manifold assembly to pressure regulator) 5. Pressure regulator 6. Canister purge hose (for california only) 7....

  • 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

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-82 1. Cylinder-#1 intake air pressure sensor 2. Cylinder-#2 intake air pressure sensor hose 3. Cylinder-#2 intake air pressure sensor 4. Isc (idle speed control) unit coupler 5. Isc (idle speed control) unit 6. Isc (idle speed control) unit inlet hose 7. Cyl...

  • Page 110

    Cable routing (for xv19cs(c)/ xv19c(c)) 2-83.

  • Page 111

    3 periodic checks and adjustments periodic maintenance ............................................................................ 3-1 introduction ....................................................................................... 3-1 periodic maintenance chart for the emission control system ...

  • Page 112

    Chassis ....................................................................................................... 3-21 adjusting the rear disc brake .................................................. 3-21 checking the brake fluid level................................................. 3-21 checking the...

  • Page 114: Periodic Maintenance

    Periodic maintenance 3-1 eas20450 periodic maintenance eas20460 introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and re...

  • Page 115: Periodic Maintenance

    Periodic maintenance 3-2 6 * wheels • check runout and for dam- age. • replace if necessary. √ √ √ √ √ 7 * tires • check tread depth and for damage. • replace if necessary. • check air pressure. • correct if necessary. √ √ √ √ √ 8 * wheel bearings • check bearings for smooth operation. • replace if ...

  • Page 116: Periodic Maintenance

    Periodic maintenance 3-3 * since these items require special tools, data and technical skills, have a yamaha dealer perform the service. Note: from 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. Eau38440 note: • air filter • this mod...

  • Page 117: Engine

    Engine 3-4 eas20470 engine eas20530 adjusting the valve clearance the following procedure applies to all of the valves. Note: • the valve clearance is automatically adjusted by the hydraulic valve lifter. However, there are times when the valve clearance needs to be adjusted manually. If this is the...

  • Page 118: Engine

    Engine 3-5 8. Remove: • fuel tank damper “1” • cylinder head breather hose “2” 9. Disconnect: • oil tank breather hose “3” • fuel outlet hose “4” 10.Remove: • front cylinder head cover “1” • rear cylinder head cover “2” note: due to the small clearance between the frame and the rear cylinder head co...

  • Page 119: Engine

    Engine 3-6 d. Measure the valve clearance with a thickness gauge. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ piston #2 tdc (front cylinder) a. Turn the crankshaft counterclockwise from the piston #1 tdc by 408 degrees. B. When piston #2 is at ...

  • Page 120: Engine

    Engine 3-7 d. Hold the adjusting screw to prevent it from moving and tighten the locknut to specifica- tion. E. Measure the valve clearance again. F. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained...

  • Page 121: Engine

    Engine 3-8 6. Install: • fuel tank refer to “fuel tank” on page 6-1. 7. Adjust: • throttle body synchronization ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Start the engine and let it warm up for several minutes, and then let it run at specified en- gine idling speed. B. With throttle body ...

  • Page 122: Engine

    Engine 3-9 b. Turn the adjusting nut “2” in direction “a” or “b” until the specified throttle cable free play is obtained. C. Tighten the locknut “1”. Warning ewa12910 after adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that th...

  • Page 123: Engine

    Engine 3-10 eas20700 checking the ignition timing note: prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure all connections are tight and free of corrosion. 1. Stand the vehicle on a level surface. 2. Remove: (for xv19s(c)/ xv19m(c)/ xv19cts(c...

  • Page 124: Engine

    Engine 3-11 note: align the mark “a” on the shift pedal shaft with the slot in the shift pedal. Eas20750 checking the engine oil level 1. Stand the vehicle on a level surface. Note: • place the vehicle on a suitable stand. • make sure the vehicle is upright. 2. Start the engine, warm it up for appro...

  • Page 125: Engine

    Engine 3-12 5. Remove: • engine oil drain bolts (crankcase) “1” (along with the gaskets) 6. Drain: • engine oil (completely from the oil tank and crankcase) 7. If the oil filter cartridge is also to be replaced, perform the following procedure. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Re...

  • Page 126: Engine

    Engine 3-13 caution: ec1d71008 when starting the engine make sure the dip- stick is securely fitted into the oil tank. 12.Fill: (when engine is disassembled) • crankcase and oil tank (with the specified amount of the recom- mended engine oil) 13.Install: • engine oil filler cap 14.Start the engine, ...

  • Page 127: Engine

    Engine 3-14 4. Install: • transfer gear oil check bolt eas20850 changing the transfer gear oil 1. Remove: • muffler • exhaust pipes refer to “engine removal” on page 5-1. 2. Place a container under the transfer gear oil drain bolt. 3. Remove: • straight plug “1” • transfer gear oil drain bolt “2” 4....

  • Page 128: Engine

    Engine 3-15 • when refilling, be careful that water does not enter the clutch fluid reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock. Caution: eca13420 clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any ...

  • Page 129: Engine

    Engine 3-16 4. Remove: • air filter element “1” 5. Check: • air filter element damage → replace. Note: the air filter needs more frequent service if you are riding in unusually wet or dusty areas. 6. Install: • air filter case cover caution: ec1d71002 never operate the engine without the air filter ...

  • Page 130: Engine

    Engine 3-17 3. Install: • fuel tank refer to “fuel tank” on page 6-1. • rider seat bracket assembly • rider seat refer to “general chassis” on page 4-1. Eas21050 checking the cylinder head breather hose 1. Remove: • rider seat • rider seat bracket assembly refer to “general chassis” on page 4-1. • f...

  • Page 131: Engine

    Engine 3-18 1. Check: • front exhaust pipe “1” • rear exhaust pipe “2” • muffler “3” • muffler bracket “4” cracks/damage → replace. • gaskets “5” exhaust gas leaks → replace. 2. Check: tightening torque • front exhaust pipe nuts “6” • front exhaust pipe and rear exhaust pipe bolt “7” • rear exhaust ...

  • Page 132: Engine

    Engine 3-19 eas21090 checking the canister (for california only) (for xv19sc/ xv19mc/ xv19ctsc/ xv19ctmc) 1. Remove: • horn 1 refer to “throttle bodies” on page 6-7. 2. Check: • canister “1” • canister purge hose “2” • canister breather hose “3” • fuel tank breather/overflow hose “4” cracks/damage →...

  • Page 133: Engine

    Engine 3-20 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Check: • exup cable free play (at the exup valve pul- ley) “a” and “b” 4. Adjust: • exup cable free play ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen both locknuts “1”. B. Turn both adjusting bolts “2” in or out until th...

  • Page 134: Chassis

    Chassis 3-21 eas21140 chassis eas21190 adjusting the rear disc brake 1. Check: • brake pedal position (distance “a” from the top of the rider footrest to the top of the brake pedal) out of specification → adjust. 2. Adjust: • brake pedal position ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. ...

  • Page 135: Chassis

    Chassis 3-22 2. Remove: • rider seat refer to “general chassis” on page 4-1. 3. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper level. Warning ewa13090 • use only the designated brake fluid. Other brake fluids may cause the rubber seals to ...

  • Page 136: Chassis

    Chassis 3-23 eas21280 checking the front brake hoses the following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hoses “1” cracks/damage/wear → replace. 2. Check: • brake hose clamps loose → tighten the clamp bolt. 3. Hold the vehicle upright and apply the brak...

  • Page 137: Chassis

    Chassis 3-24 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21350 bleeding the hydraulic brake system warning ewa13100 bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake ope...

  • Page 138: Chassis

    Chassis 3-25 warning ewa13110 after bleeding the hydraulic brake system, check the brake operation. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • rider seat refer to “general chassis” on page 4-1. Eas21380 adjusting the shift pedal note: the shift pedal position is determined by th...

  • Page 139: Chassis

    Chassis 3-26 eas21430 adjusting the drive belt slack note: the drive belt slack must be checked at the tight- est point on the belt. Caution: eca14950 a drive belt that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause ...

  • Page 140: Chassis

    Chassis 3-27 note: using the alignment marks on each side of the swingarm, make sure that both belt pullers are in the same position for proper wheel alignment. D. Tighten the locknuts to specification. E. Tighten the rear wheel axle nut to specifica- tion. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲...

  • Page 141: Chassis

    Chassis 3-28 c. Loosen the lower ring nut completely, and then tighten it to specification with a steering nut wrench. Warning ewa13140 do not overtighten the lower ring nut. D. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding ...

  • Page 142: Chassis

    Chassis 3-29 b. Turn the adjusting ring “3” in direction “a” or “b”. C. Tighten the locknut to specification. Caution: eca13600 always tighten the locknut against the ad- justing nut and torque it to specification. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas21650 checking the tires the fol...

  • Page 143: Chassis

    Chassis 3-30 warning ewa13190 it is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, re- place the tire immediately. 2. Check: • tire surfaces damage/wear → replace the tire. Warning ewa14080 • do not use a tubeless tire on a wheel de- signed only for tube tires to...

  • Page 144: Chassis

    Chassis 3-31 should always be by the same manufacturer and of the same design. No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by yamaha is used on this vehicle. Warning ewa13210 new tires have a relatively low grip on the road surface ...

  • Page 145: Chassis

    Chassis 3-32 note: hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. Eas21700 lubricating the levers lubricate the pivoting point and metal-to-metal moving parts of the levers. Eas1d77003 lubricating the pedals lubricate the pi...

  • Page 146: Electrical System

    Electrical system 3-33 eas21750 electrical system eas21760 checking and charging the battery refer to “electrical components” on page 7-67. Eas21770 checking the fuses refer to “electrical components” on page 7-67. Eas21790 replacing the headlight bulbs (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c...

  • Page 147: Electrical System

    Electrical system 3-34 • headlight bulb cover “1” b. Disconnect: • headlight coupler “1” c. Detach: • headlight bulb holder “2” d. Remove: • headlight bulb warning ewa13320 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down...

  • Page 148: Electrical System

    Electrical system 3-35 6. Install: • headlight bulb secure the new headlight bulb with the head- light bulb holder. Caution: eca13690 avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux wi...

  • Page 149: Electrical System

    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

    Electrical system 3-37.

  • Page 151: Chassis

    4 chassis general chassis....................................................................................... 4-1 removing the windshield ............................................................... 4-2 assembling the windshield ........................................................... 4-2 i...

  • Page 152

    Rear brake ............................................................................................... 4-47 introduction ..................................................................................... 4-53 checking the rear brake disc.................................................... 4-5...

  • Page 153

    Belt drive.................................................................................................. 4-90 removing the drive belt and drive pulley ........................... 4-92 checking the drive belt ............................................................... 4-92 installing the driv...

  • Page 154: General Chassis

    General chassis 4-1 eas21830 general chassis removing the windshield (for xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks 1 windshield 1 2 windshield bracket brace 1 3 windshield bracket (left and right) 2 4 windshield brace (left and right) 2 5 windshield screen 1 6 windshield holder...

  • Page 155: General Chassis

    General chassis 4-2 et1d71039 removing the windshield 1. Remove: • windshield ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Insert the key “1” into the windshield lock, turn it clockwise and then remove the key. B. Remove the windshield by pushing it forward, and then pulling it upward as sho...

  • Page 156: General Chassis

    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: General Chassis

    General chassis 4-4 removing the sidebags and backrest (for xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks 1 sidebag (left and right) 2 note: water can be harmful to untreated leather. Use yamaha saddle soap or another quality brand according to the manufacturer’s direc- tions to cle...

  • Page 158: General Chassis

    General chassis 4-5 et1d71041 removing the backrest 1. Remove: • backrest ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Open the sidebag lids. B. Insert the key “1” into the backrest lock, turn it counterclockwise, and then remove the key. C. Pull the lever “1” on each side of the backrest up...

  • Page 159: General Chassis

    General chassis 4-6 b. Push the rear of the backrest down smoothly but forcefully to lock it in place and make sure that the lever hook “1” on each side is secure- ly fit over its holder “2”. Warning ew1d71017 both lever hooks must be securely fitted over their holder. If the backrest is loose, a pa...

  • Page 160: General Chassis

    General chassis 4-7 removing the sidebag brackets (for xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks sidebag/backrest refer to “general chassis” on page 4-1. 1 passenger footrest (left and right) 2 2 sidebag bracket brace 1 3 sidebag bracket (left and right) 2 note: remove only one ...

  • Page 161: General Chassis

    General chassis 4-8 et1d71047 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 height 12.0 mm (0.47 in) a.

  • Page 162: General Chassis

    General chassis 4-9 removing the seats and side covers order job/parts to remove q’ty remarks 1 rider seat 1 2 passenger seat 1 3 tool kit 1 4 tool kit tray 1 5 rider seat bracket assembly 1 6 right side cover 1 7 left side cover 1 8 seat lock cable assembly 1 for installation, reverse the removal p...

  • Page 163: General Chassis

    General chassis 4-10 removing the headlight (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks 1 headlight cover 1 2 air temperature sensor coupler 1 disconnect. 3 air temperature sensor 1 4 headlight (low beam) coupler 1 disconnect. 5 headlight (high beam) coupl...

  • Page 164: General Chassis

    General chassis 4-11 removing the headlight (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks 1 headlight lens unit 1 2 headlight coupler 1 disconnect. 3 front left turn signal/position light coupler 1 disconnect. 4 front right turn signal/position light coupler 1 disconnect. 5 main s...

  • Page 165: General Chassis

    General chassis 4-12 removing the battery order job/parts to remove q’ty remarks tool kit tray/seat bracket refer to “general chassis” on page 4-1. 1 ecu band 1 2 ecu (electronic control unit) 1 3 coupler tray 1 4 negative terminal cover 1 5 negative battery lead 1 disconnect. 6 positive battery lea...

  • Page 166: General Chassis

    General chassis 4-13 16 relay unit 1 17 headlight 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 15 19 14 12 19 20 8 5 6 7 2 1 3 9 10 (3) 11 4.

  • Page 167: General Chassis

    General chassis 4-14 removing the air filter case (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. Pressure regulator cover refer to “throttle bodies” on page 6-7. 1 ...

  • Page 168: General Chassis

    General chassis 4-15 15 air filter case bracket 1 16 air filter case joint clamp screw 2 loosen. 17 air 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...

  • Page 169: General Chassis

    General chassis 4-16 removing the air filter case (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. Pressure regulator cover refer to “throttle bodies” on page 6-7. 1 left handlebar switch c...

  • Page 170: General Chassis

    General chassis 4-17 15 air filter case breather hose 1 1 disconnect. 16 air filter case breather hose 2 1 disconnect. 17 isc (idle speed control) unit inlet hose 1 disconnect. 18 steering lock cover 1 19 fuel tank bracket 2 (front side) 1 20 air filter case bracket 1 21 air filter case joint clamp ...

  • Page 171: Front Wheel

    Front wheel 4-18 eas21870 front wheel removing the front wheel and brake discs (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the front wheel is elevated. 1 right front fender stay 1 2 left front fender stay...

  • Page 172: Front Wheel

    Front wheel 4-19 14 collar 2 15 front brake disc cover 1 16 front brake disc 2 for installation, reverse the removal proce- dure. Removing the front wheel and brake discs (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks t r . . 7 nm (0.7 m • kg, 5.1 ft • ib) t ...

  • Page 173: Front Wheel

    Front wheel 4-20 removing the front wheel and brake discs (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the front wheel is elevated. 1 front brake hose holder 2 2 right front brake hose holder bracket 1 3 left front brake hose ho...

  • Page 174: Front Wheel

    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: Front Wheel

    Front wheel 4-22 eas21900 removing the front wheel 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) • right front fender stay “1” • left front fender stay ...

  • Page 176: Front Wheel

    Front wheel 4-23 2. Check: • tire • front wheel damage/wear → replace. Refer to “checking the tires” on page 3-29 and “checking the wheels” on page 3-31. 3. Measure: • radial wheel runout “1” • lateral wheel runout “2” over the specified limits → replace. 4. Check: • wheel bearings front wheel turns...

  • Page 177: Front Wheel

    Front wheel 4-24 c. Turn the front wheel 90° so that the “x 1 ” mark is positioned as shown. D. Release the front wheel. E. When the wheel stops, put an “x 2 ” mark at the bottom of the wheel. F. Repeat steps (d) through (f) several times un- til all the marks come to rest at the same spot. G. The s...

  • Page 178: Front Wheel

    Front wheel 4-25 2. Check: • front brake discs refer to “checking the front brake discs” on page 4-40. 3. Lubricate: • oil seal lips 4. Install: • front wheel axle note: install the tire and wheel with the mark “1” point- ing in the direction of wheel rotation. 5. Tighten: • front wheel axle • front...

  • Page 179: Front Wheel

    Front wheel 4-26.

  • Page 180: Rear Wheel

    Rear wheel 4-27 eas22020 rear wheel removing the rear fender order job/parts to remove q’ty remarks rider seat/passenger seat/tool kit tray refer to “general chassis” on page 4-1. 1 sub-wire harness 1 coupler 1 disconnect. 2 rear fender bracket 2 for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) 3 rear...

  • Page 181: Rear Wheel

    Rear wheel 4-28 removing the rear wheel order job/parts to remove q’ty remarks note: place the vehicle on a suitable stand so that the rear wheel is elevated. Muffler refer to “engine removal” on page 5-1. 1 upper drive belt cover 1 2 rear brake caliper 1 3 rear brake pad 2 4 brake pad spring 2 5 dr...

  • Page 182: Rear Wheel

    Rear wheel 4-29 14 collar 1 silver 15 rear wheel 1 for installation, 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 13...

  • Page 183: Rear Wheel

    Rear wheel 4-30 removing the rear brake disc and rear wheel drive hub order job/parts 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 wheel drive hub d...

  • Page 184: Rear Wheel

    Rear wheel 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 1 new ls 5.

  • Page 185: Rear Wheel

    Rear wheel 4-32 eas28760 removing the rear wheel (disc) 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 stand so that the rear wheel is elevated. 2. Remove: • rear brake calipe...

  • Page 186: Rear Wheel

    Rear wheel 4-33 eas22110 checking the rear wheel drive hub 1. Check: • rear wheel drive hub cracks/damage → replace. • rear wheel drive hub dampers damage/wear → replace. Eas22130 checking and replacing the rear wheel pulley 1. Check: • rear wheel pulley surface plating has come off → replace the re...

  • Page 187: Rear Wheel

    Rear wheel 4-34 note: temporarily tighten the wheel axle nut. 5. Adjust: • drive belt 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: Front Brake

    Front brake 4-35 eas22210 front brake removing the front brake pads order job/parts to remove q’ty remarks the following procedure applies to both of the 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 bra...

  • Page 189: Front Brake

    Front brake 4-36 removing the front brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-24. 1 right rearview mirror 1 2 brake master cylinder reservoir cap 1 3 brake master cylinder reservoir diaphragm hold- er 1 4 ...

  • Page 190: Front Brake

    Front brake 4-37 disassembling 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 pro- cedure. New 1 3 2 4 new s.

  • Page 191: Front Brake

    Front brake 4-38 removing the front brake calipers order job/parts to remove q’ty remarks the following procedure applies to both of the front brake calipers. Brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-24. 1 brake hose holder 1 2 front brake hose union bolt 1 3 coppe...

  • Page 192: Front Brake

    Front brake 4-39 disassembling the front brake calipers order job/parts to remove q’ty remarks the following 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 pist...

  • Page 193: Front Brake

    Front brake 4-40 eas22220 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the...

  • Page 194: Front Brake

    Front brake 4-41 d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. F. If the brake disc deflection cannot be brought within specification, replace the brake disc. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ...

  • Page 195: Front Brake

    Front brake 4-42 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • brake pad pin • brake pad clips • front brake caliper 4. Check: • brake fluid level below the minimum level mark “a” → add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” on pa...

  • Page 196: Front Brake

    Front brake 4-43 b. Remove the brake caliper piston seals and dust seals. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22390 checking the front brake calipers 1. Check: • brake caliper pistons “1” rust/scratches/wear → replace the brake caliper pistons. • brake caliper cylinders “2” scratche...

  • Page 197: Front Brake

    Front brake 4-44 caution: eca14170 when installing the brake hose onto the brake caliper “1”, make sure the brake pipe “a” touches the projection “b” on the brake caliper. 2. Remove: • front brake caliper 3. Install: • brake pads • brake pad spring • brake pad pin • brake pad clips • front brake cal...

  • Page 198: Front Brake

    Front brake 4-45 eas22500 checking the front brake master cylinder 1. Check: • brake master cylinder “1” damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstruction → blow out with compressed air. 2. Check: • brake master cylinder kit damage/scratches/we...

  • Page 199: Front Brake

    Front brake 4-46 • turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.G., wire harness, cables, leads). Correct if necessary. 3. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) warning ewa13540 • use...

  • Page 200: Rear Brake

    Rear brake 4-47 eas22550 rear brake removing the rear brake 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 t r . . 27 nm (2.7 m • kg, 19 ft • ib) t...

  • Page 201: Rear Brake

    Rear brake 4-48 removing the rear brake master cylinder order job/parts to remove q’ty remarks brake fluid drain. Refer to “bleeding the hydraulic brake system” on page 3-24. 1 brake fluid reservoir cap 1 2 brake fluid reservoir diaphragm holder 1 3 brake fluid reservoir diaphragm 1 4 brake fluid re...

  • Page 202: Rear Brake

    Rear brake 4-49 16 brake master cylinder 1 for installation, reverse the removal proce- 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...

  • Page 203: Rear Brake

    Rear brake 4-50 disassembling the rear 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 circlip 1 5 brake hose joint 1 6 o-ring 1 7 brake master cylinder body 1 for assembly, reverse the disassembly pro- cedure. 1 2 3 4 5 6 7 new ...

  • Page 204: Rear Brake

    Rear brake 4-51 removing the rear brake caliper order job/parts to remove q’ty remarks brake fluid drain. 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 installat...

  • Page 205: Rear Brake

    Rear brake 4-52 disassembling the rear brake 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. S 2 1 4 3 new bf t r . . 6 nm (0.6 m • kg, 4.3 ft •...

  • Page 206: Rear Brake

    Rear brake 4-53 eas22560 introduction warning ewa14100 disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • never disassemble brake components un- less absolutely necessary. • if any connection on the hydraulic brake system is disconnected, the ...

  • Page 207: Rear Brake

    Rear brake 4-54 note: always install new brake pads and brake pad springs as a set. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. B. Loosen the bleed screw and push the brake...

  • Page 208: Rear Brake

    Rear brake 4-55 b. Remove the brake caliper piston seal and dust seal. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas22640 checking the rear brake caliper 1. Check: • brake caliper piston “1” rust/scratches/wear → replace the brake caliper piston. • brake caliper cylinder “2” scratches/wear →...

  • Page 209: Rear Brake

    Rear brake 4-56 2. Remove: • rear brake caliper 3. Install: • brake pads • brake pad springs • rear brake caliper bolts • rear brake caliper refer to “replacing the rear brake pads” on page 4-53. 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) warning ew...

  • Page 210: Rear Brake

    Rear brake 4-57 eas22720 checking the rear brake master cylinder 1. Check: • brake master cylinder damage/scratches/wear → replace. • brake fluid delivery passages (brake master cylinder body) obstruction → blow out with compressed air. 2. Check: • brake master cylinder kit damage/scratches/wear → r...

  • Page 211: Rear Brake

    Rear brake 4-58 5. Check: • brake pedal operation soft or spongy feeling → bleed the brake sys- tem. Refer to “bleeding the hydraulic brake system” on page 3-24. 6. Adjust: • brake pedal position refer to “adjusting the rear disc brake” on page 3-21. 7. Adjust: • rear brake light operation timing re...

  • Page 212: Handlebar

    Handlebar 4-59 eas22840 handlebar removing the handlebar (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks headlight body refer to “general chassis” on page 4-1. 1 rearview mirror 2 2 plastic clamp 2 3 front brake light switch connector 2 disconnect. 4 front bra...

  • Page 213: Handlebar

    Handlebar 4-60 15 handlebar grip 1 16 upper handlebar holder 1 17 handlebar 1 18 hose guide 1 19 lower handlebar holder 1 for installation, reverse the removal 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 ...

  • Page 214: Handlebar

    Handlebar 4-61 removing the handlebar (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks headlight bracket refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. 1 left handlebar switch coupler 4 disconnect. 2 right handlebar switch coupler 3 disconnect. 3 ...

  • Page 215: Handlebar

    Handlebar 4-62 16 handlebar grip 1 17 main switch cover 1 18 lead holder 2 19 upper handlebar holder 1 20 handlebar 1 21 lower handlebar holder 2 for installation, reverse the removal proce- dure. Removing the handlebar (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks t r . . 10 nm (...

  • Page 216: Handlebar

    Handlebar 4-63 eas22860 removing the handlebar 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • handlebar grip “1” note: blow compressed air between the handlebar and the left handlebar grip, and gradua...

  • Page 217: Handlebar

    Handlebar 4-64 warning ewa13700 do not touch the handlebar grip until the rub- ber adhesive has fully dried. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Install: • left handlebar switch “1” note: align the projection “a” on the left handlebar switch with the hole “b” in the handlebar. 7. In...

  • Page 218: Handlebar

    Handlebar 4-65 throttle cable free play 4.0–6.0 mm (0.16–0.24 in).

  • Page 219: Front Fork

    Front fork 4-66 eas22950 front fork removing the front fork legs (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Windshield bracket (left and right) for xv19cts(c)/ xv19ctm(c) lower handlebar hold...

  • Page 220: Front Fork

    Front fork 4-67 12 front fork leg 1 for installation, reverse the removal proce- dure. Removing the front fork legs (for 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 f...

  • Page 221: Front Fork

    Front fork 4-68 removing the front fork legs (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. Front wheel refer to “front wheel” on page 4-18. 1 upper bracket pinch bolt 4 loosen. 2 cap bolt 2 loosen. 3 lower bracket pin...

  • Page 222: Front Fork

    Front fork 4-69 disassembling the front fork legs order job/parts to remove q’ty remarks the following procedure applies to both of the front fork legs. 1 protector 1 for xv19cs(c)/ xv19c(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 r...

  • Page 223: Front Fork

    Front fork 4-70 17 inner tube bushing 1 18 spring 1 19 oil flow stopper 1 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 (2.3 m • kg, 17 ft • ...

  • Page 224: Front Fork

    Front fork 4-71 eas22960 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. Note: place the vehicle on a suitable stand so t...

  • Page 225: Front Fork

    Front fork 4-72 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas23010 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: • inner tube • outer tube bends/damage/scratches → replace. Warning ewa13650 do not attempt to straighten a bent inner tub...

  • Page 226: Front Fork

    Front fork 4-73 2. Lubricate: • inner tube’s outer surface 3. Install: • inner tube (in the outer tube) 4. Install: • copper washer • damper rod bolt 5. Tighten: • damper rod bolt “1” note: while holding the damper rod assembly with the damper rod holder “2” and t-handle “3”, tighten the damper rod ...

  • Page 227: Front Fork

    Front fork 4-74 8. Install: • oil seal clip “1” note: adjust the oil seal clip so that it fits into the outer tube’s groove. 9. Install: • dust seal “1” (with the fork seal driver weight “2”) 10.Fill: • front fork leg (with the specified amount of the recom- mended fork oil) 11.Measure: • front fork...

  • Page 228: Front Fork

    Front fork 4-75 eas23050 installing the front fork legs (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) the following procedure applies to both of the front fork legs. 1. Install: • lower front fork cover “1” • front fork leg “2” • upper bracket “3” temporarily tighten the lower bracket pinch bolts...

  • Page 229: Front Fork

    Front fork 4-76 eas1d77008 installing the front fork legs (for xv19cs(c)/ xv19c(c)) the following procedure applies to both of the front fork legs. 1. Install: • front fork leg “1” temporarily tighten the lower bracket pinch bolts and steering stem bolt. Note: make sure the inner tube end is flush w...

  • Page 230: Steering Head

    Steering head 4-77 eas23090 steering head removing the lower bracket (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks lower handlebar holder refer to “handlebar” on page 4-59. Upper bracket/front fork legs refer to “front fork” on page 4-66. 1 headlight bracket...

  • Page 231: Steering Head

    Steering head 4-78 13 bearing outer race 2 for installation, reverse the removal proce- dure. Removing 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...

  • Page 232: Steering Head

    Steering head 4-79 removing the lower bracket (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks lower handlebar holders refer to “handlebar” on page 4-59. Front fork legs refer to “front fork” on page 4-66. 1 plate 1 2 front brake hose guide 1 3 front brake hose joint 1 4 front brake ...

  • Page 233: Steering Head

    Steering head 4-80 16 rubber washer 1 17 lower ring nut 1 18 lower bracket 1 19 upper bearing cover 1 20 upper bearing 1 21 lower bearing 1 22 dust seal 1 23 bearing outer race 2 for installation, reverse the removal proce- dure. Removing the lower bracket (for xv19cs(c)/ xv19c(c)) order job/parts t...

  • Page 234: Steering Head

    Steering head 4-81 eas23110 removing the lower bracket 1. Stand the vehicle on a level surface. Warning ewa13120 securely support the vehicle so that there is no danger of it falling over. 2. Remove: • upper ring nut • rubber washer • lower ring nut “1” • lower bracket warning ewa13730 securely supp...

  • Page 235: Steering Head

    Steering head 4-82 2. Install: • lower ring nut “1” • rubber washer “2” • upper ring nut “3” • lock washer “4” refer to “checking and adjusting the steering head” on page 3-27. 3. Install: • front brake hose joint “1” • front brake hose guide “2” note: • make sure that the projection “a” on the lowe...

  • Page 236

    Rear shock absorber assembly and swingarm 4-83 et1d71001 rear shock absorber assembly and swingarm removing the rear shock absorber assembly and swingarm order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-27. Exhaust pipes refer to “engine removal” on page 5-1. Brake m...

  • Page 237

    Rear shock absorber assembly and swingarm 4-84 9 pivot shaft nut/washer 1/1 10 pivot shaft 1 11 rear shock absorber and swingarm assembly 1 12 lower drive belt cover 1 for installation, reverse the removal proce- dure. Removing the rear shock absorber assembly and swingarm order job/parts to remove ...

  • Page 238

    Rear shock absorber assembly and swingarm 4-85 removing the rear shock absorber and swingarm order job/parts to remove q’ty remarks 1 self-locking nut/washer/bolt 1/2/1 2 oil seal/collar/bushing/bearing 2/2/1/2 3 swingarm 1 4 self-locking nut/washer/bolt 1/1/1 5 connecting arm 2 6 o-ring 4 7 spacer ...

  • Page 239

    Rear shock absorber assembly and swingarm 4-86 eas23180 handling the rear shock absorber warning ewa13740 this rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be...

  • Page 240

    Rear shock absorber assembly and swingarm 4-87 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas23240 checking the rear shock absorber assembly 1. Check: • rear shock absorber rod bends/damage → replace the rear shock absorber assembly. • rear shock absorber gas leaks/oil leaks → replace the rea...

  • Page 241

    Rear shock absorber assembly and swingarm 4-88 2. Install: • bearings “1”, “2”, “3” (to the relay arm) • oil seals “4”, “5” (to the relay arm) 3. Lubricate: • bushings • oil seals • o-rings • collar note: apply grease only to the collar between the con- necting arms and rear shock absorber. 4. Insta...

  • Page 242

    Rear shock absorber assembly and swingarm 4-89 6. Tighten: • connecting-arm-to-relay-arm nut • rear-shock-absorber-assembly-to-relay-arm nut • relay-arm-to-swingarm nut eas28780 installing the swingarm 1. Lubricate: • bearings • collars • oil seals • pivot shaft 2. Install: • bearings “1” (to swinga...

  • Page 243: Belt Drive

    Belt drive 4-90 eas23510 belt drive removing the drive belt and drive pulley order job/parts to remove q’ty remarks rear wheel refer to “rear wheel” on page 4-27. Rear shock absorber assembly and swingarm refer to “rear shock absorber as- sembly and swingarm” on page 4-83. 1 rectifier/regulator cove...

  • Page 244: Belt Drive

    Belt drive 4-91 13 drive pulley 1 for installation, reverse the removal proce- dure. Removing the drive 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, ...

  • Page 245: Belt Drive

    Belt drive 4-92 eas23520 removing the drive belt and drive pulley note: loosen the drive pulley nut before removing the rear wheel. 1. Loosen: • drive pulley nut “1” note: when loosening the drive pulley nut, press down on the brake pedal so the drive pulley does not move. Eas23530 checking the driv...

  • Page 246: Belt Drive

    Belt drive 4-93 3. Install: • swingarm • rear shock absorber refer to “rear shock absorber as- sembly and swingarm” on page 4-83. • rear wheel refer to “rear wheel” on page 4-27. 4. Tighten: • drive pulley nut note: • when tightening the drive pulley nut, press down on the brake pedal so the drive p...

  • Page 247: Engine

    5 engine engine removal ........................................................................................ 5-1 installing the shift pedal assembly......................................... 5-8 checking the oil cooler (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) ................................

  • Page 248

    Clutch ........................................................................................................ 5-53 removing the clutch ..................................................................... 5-64 removing the primary drive gear ............................................ 5-64 removi...

  • Page 249

    Crankcase ................................................................................................ 5-94 disassembling the crankcase.................................................... 5-97 checking the crankcase .............................................................. 5-97 checking the...

  • Page 250: Engine Removal

    Engine removal 5-1 eas23710 engine removal removing the muffler and exhaust pipes (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks 1 rear brake light switch 1 2 right rider footrest assembly 1 3 exup valve pulley cover 1 4 exup cable 2 disconnect. 5 o 2 sensor ...

  • Page 251: Engine Removal

    Engine removal 5-2 15 gasket 1 for installation, reverse the removal proce- dure. Removing the muffler and exhaust pipes (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks 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...

  • Page 252: Engine Removal

    Engine removal 5-3 removing the muffler and exhaust pipes (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks rider seat refer to “general chassis” on page 4-1. 1 exup valve pulley cover 1 2 muffler 1 3 muffler bracket 1 4 gasket 1 5 exup cable 2 disconnect. 6 o 2 sensor coupler 1 disco...

  • Page 253: Engine Removal

    Engine removal 5-4 removing the cylinder-#1 ignition coils and sidestand (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks rider seat/left side cover/battery box/air filter case refer to “general chassis” on page 4-1. Fuel tank/sub-fuel tank refer to “fuel tank”...

  • Page 254: Engine Removal

    Engine removal 5-5 6 cylinder-#1 ignition coil bracket 1 7 horn 1 connector 2 except for california disconnect. 8 horn 1 1 except for california 9 horn 2 coupler 1 10 horn 2 1 11 shift rod 1 12 rear brake light switch coupler 1 13 left rider footrest assembly 1 14 shift pedal shaft bracket 1 15 shif...

  • Page 255: Engine Removal

    Engine removal 5-6 removing the right ignition coils and sidestand (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks rider seat/left side cover/battery box/air filter case refer to “general chassis” on page 4-1. Fuel tank/sub-fuel tank refer to “fuel tank” on page 6-1. Throttle body/i...

  • Page 256: Engine Removal

    Engine removal 5-7 6 right ignition coil bracket 1 7 horn 1 connector 2 except for california disconnect. 8 horn 1 1 except for california 9 horn 2 coupler 1 10 horn 2 1 11 shift rod 1 12 rear brake light switch coupler 1 13 shift pedal assembly 1 14 sidestand switch 1 15 sidestand 1 for installatio...

  • Page 257: Engine Removal

    Engine removal 5-8 et1d71029 installing the shift pedal assembly 1. Assemble: (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) • shift pedal (heel side) “1” • shift pedal (toe side) “2” note: align the mark “a” on the pin on the toe side with the mark “b” on the heel side. 2. Install: (for xv19s(c)/...

  • Page 258: Engine Removal

    Engine removal 5-9 removing the oil cooler and oil filter bracket order job/parts to remove q’ty remarks 1 oil filter cartridge 1 2 oil cooler outlet hose 1 for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) 3 oil cooler inlet hose 1 for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) 4 oil cooler 1 for xv19...

  • Page 259: Engine Removal

    Engine removal 5-10 et1d71028 checking the oil cooler (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 1. Check: • oil cooler fins obstruction → clean. Apply compressed air to the rear of the oil cooler. Damage → repair or replace. Note: straighten any flattened fins with a thin, flathead screwdrive...

  • Page 260: Engine Removal

    Engine removal 5-11 disconnecting the leads order job/parts to remove q’ty remarks drive pulley case refer to “transfer gear case” on page 5-86. 1 spark plug cap 2 2 stator coil lead 1 3 neutral switch coupler 1 disconnect. 4 neutral switch lead 1 5 lead holder bracket 1 6 wire harness guide 1 7 thr...

  • Page 261: Engine Removal

    Engine removal 5-12 15 speed sensor lead 1 for installation, 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 • kg, 5.1 ft • ...

  • Page 262: Engine Removal

    Engine removal 5-13 removing the engine order job/parts to remove q’ty remarks note: place a suitable stand under the frame and engine. Transfer gear case refer to “transfer gear case” on page 5-86. 1 engine mounting bolt (right upper side) 2 2 engine mounting bolt (left upper side) 2 3 engine brack...

  • Page 263: Engine Removal

    Engine removal 5-14 a: for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) b: for xv19cs(c)/ xv19c(c) 14 engine mounting nut (rear upper side) 1 15 engine mounting bolt (rear upper side) 1 16 engine bracket nut (rear upper side) 2 17 engine bracket bolt (rear upper side) 2 18 engine bracket (rear upper s...

  • Page 264: Engine Removal

    Engine removal 5-15 et1d71019 removing the engine 1. Loosen: • spacer bolt note: loosen the spacer bolt with the pivot shaft wrench “1”. Eas23720 installing the engine 1. Install: • spacer bolt “1” • engine “2” • washer “3” • engine mounting bolt (rear lower side) “4” • engine mounting nut (rear low...

  • Page 265: Engine Removal

    Engine removal 5-16 5. Install: • engine brackets (front upper side) “1” • engine bracket bolts (front upper side) “2” • engine bracket nuts (front upper side) “3” • engine cross-member bracket “4” • engine cross-member bracket bolts “5” • engine mounting bolt (front upper side) “6” • engine mountin...

  • Page 266: Camshafts

    Camshafts 5-17 eas23750 camshafts removing the camshaft sprocket cover order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. Air filter case refer to “general chassis” on page 4-1. Muffler/exhaust pipes refer to “engine removal” on page 5-1. 1 spark plug cap 4 disconnect...

  • Page 267: Camshafts

    Camshafts 5-18 removing the cylinder head covers order job/parts to remove q’ty remarks 1 cylinder head breather hose 1 2 oil tank breather hose 1 disconnect. 3 wire harness guide 1 4 fuel tank damper 1 5 fuel outlet hose 1 disconnect. 6 cylinder head cover bolt 8 l = 40 mm (1.57 in) 7 cylinder head...

  • Page 268: Camshafts

    Camshafts 5-19 removing the push rods and rocker arms order job/parts to remove q’ty remarks 1 rear rocker arm base assembly 1 2 front rocker arm base assembly 1 3 rocker arm base gasket 2 4 dowel pin 4 5 pull rod 1 3 l = 286.5 mm (11.280 in) pink painting 6 pull rod 2 1 l = 288.5 mm (11.358 in) sky...

  • Page 269: Camshafts

    Camshafts 5-20 removing the valve lifters order job/parts to remove q’ty remarks front cylinder refer to “cylinders and pistons” on 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 remov...

  • Page 270: Camshafts

    Camshafts 5-21 removing the camshafts and right balancer order job/parts to remove q’ty remarks 1 camshaft driven gear 1 2 straight key 1 3 circlip 1 4 washer 1 5 conical spring washer 1 6 washer 1 7 rear cylinder camshaft gear 1 8 front cylinder camshaft gear 1 9 straight key 1 10 right balancer dr...

  • Page 271: Camshafts

    Camshafts 5-22 18 dowel pin 2 19 rear cylinder camshaft 1 20 front cylinder camshaft 1 21 right balancer 1 for installation, reverse the 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....

  • Page 272: Camshafts

    Camshafts 5-23 disassembling the camshafts order job/parts to 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 disassembly pro- cedure. 4 4 7 6 5 5 3 2 ...

  • Page 273: Camshafts

    Camshafts 5-24 et1d71030 removing the cylinder head covers 1. Remove: • front cylinder • rear cylinder “1” note: due to the small clearance between the frame and the rear cylinder head cover, the three bolts “2” cannot be removed when the cover is in place. Loosen the bolts, and then remove the cove...

  • Page 274: Camshafts

    Camshafts 5-25 2. Remove: • camshaft driven gear • straight key note: cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase. 3. Loosen: • front cylinder camshaft gear bolt “1” note: • place a folded copper washer “2” between the teeth of the front cyli...

  • Page 275: Camshafts

    Camshafts 5-26 eas23860 checking the camshafts 1. Check: • cam blue discoloration/pitting/scratches → re- place the camshaft. 2. Measure: • cam dimensions a “a” and b “b” out of specification → replace the camshaft. 3. Measure: • camshaft journal diameter (crankcase side) “a” out of specification → ...

  • Page 276: Camshafts

    Camshafts 5-27 5. Measure: • crankcase hole inside diameter “a” out of specification → replace the crank- case. 6. Measure: • camshaft cover hole inside diameter “a” out of specification → replace the camshaft cover. 7. Calculate: • camshaft-to-crankcase clearance out of specification → replace the ...

  • Page 277: Camshafts

    Camshafts 5-28 4. Measure: • rocker arm shaft outside diameter “a” out of specification → replace. 5. Calculate: • rocker arm to rocker arm shaft clearance note: calculate the clearance by subtracting the rock- er arm shaft outside diameter from the rocker arm inside diameter. Above 0.08 mm (0.003 i...

  • Page 278: Camshafts

    Camshafts 5-29 4. Measure: • valve lifter case inside diameter “a” out of specification → replace. 5. Calculate: • valve lifter-to-valve lifter case clearance note: calculate the clearance by subtracting the valve lifter outside diameter from the valve lifter case inside diameter. Above 0.072 mm (0....

  • Page 279: Camshafts

    Camshafts 5-30 2. Measure: • compressed decompression cam spring force “a” out of specification → replace the decom- pression cam spring. Eas23990 checking the oil delivery pipe 1. Check: • oil delivery pipe 1 damage → replace. Obstruction → wash and blow out with com- pressed air. • o-rings damage/...

  • Page 280: Camshafts

    Camshafts 5-31 • place a folded copper washer “3” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them. • place a folded copper washer “4” between the teeth of the right balancer drive gear and right balancer driven gear in order to lock them. • do ...

  • Page 281: Camshafts

    Camshafts 5-32 note: • cover the crankcase hole with a clean rag to prevent the straight key from falling into the crankcase. • align the punch mark “a” on the camshaft driv- en gear “1” with the punch mark “b” on the camshaft drive gear “2”. • insert a cross-headed screwdriver into one of the holes...

  • Page 282: Camshafts

    Camshafts 5-33 note: the crankshaft can be rotated smoothly when the spark plugs are removed. Warning ewa12880 be careful since the engine is hot. G. With piston #1 at tdc, count the indicated number of gear teeth and place marks “2” through “5” on the camshaft driven gear as shown. When these marks...

  • Page 283: Camshafts

    Camshafts 5-34 2. Install: • push rod covers “1” note: install the push rod covers so that their paint marks “a” are facing towards the cylinder heads. Eas24070 installing the rocker arms and push rods the following procedure applies to both cylin- ders. 1. Install: • rocker arms “1” • rocker arm sh...

  • Page 284: Camshafts

    Camshafts 5-35 bolts “2”: l = 45 mm (1.77 in) bolts “3”: l = 70 mm (2.76 in) ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas24080 installing the cylinder head covers 1. Install: • rear cylinder head cover “1” • front cylinder head cover “2” note: due to the small clearance between the frame an...

  • Page 285: Cylinder Heads

    Cylinder heads 5-36 eas24110 cylinder heads removing the cylinder heads order job/parts to remove q’ty remarks cylinder-#1 ignition coil bracket refer to “engine removal” on page 5-1. Throttle bodies/intake manifolds refer to “throttle bodies” on page 6-7. Cylinder head covers/rocker arms refer to “...

  • Page 286: Cylinder Heads

    Cylinder heads 5-37 a: for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) b: for xv19cs(c)/ xv19c(c) 13 rear exhaust pipe gasket 1 for installation, reverse the removal proce- dure. Removing the cylinder heads order job/parts to remove q’ty remarks 4 13 3 8 9 10 1 11 5 2 12 7 9 5 6 10 t r . . 20 nm (2.0...

  • Page 287: Cylinder Heads

    Cylinder heads 5-38 eas24140 removing the cylinder heads 1. Remove: • cylinder head nuts note: • loosen the nuts in the proper sequence as shown. • loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. Eas24170 checking the cylinder heads the following proce...

  • Page 288: Cylinder Heads

    Cylinder heads 5-39 eas24250 installing the cylinder heads 1. Install: • cylinder head gasket “1” • dowel pins “2” note: the “1d7” mark on the cylinder head gasket must face up and towards the left side of the cyl- inder. 2. Install: • cylinder heads • washers • cylinder head nuts note: lubricate th...

  • Page 289: Cylinder Heads

    Cylinder heads 5-40 t r . . Engine mounting bolt (right up- per side) xv19s(c)/ xv19m(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 sid...

  • Page 290: Valves and Valve Springs

    Valves and valve springs 5-41 eas24270 valves and valve springs removing the valves and valve springs order job/parts to remove q’ty remarks the following procedure applies to both cyl- inders. Cylinder heads refer to “cylinder heads” on page 5-36. 1 valve cotter 8 2 upper spring seat 4 3 valve spri...

  • Page 291: Valves and Valve Springs

    Valves and valve springs 5-42 eas24280 removing the valves the following procedure applies to all of the valves and related components. Note: before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure the valves properly seal. 1. Check: • valve seal...

  • Page 292: Valves and Valve Springs

    Valves and valve springs 5-43 2. Replace: • valve guide note: to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °c (212 °f) in an oven. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the valve guide with the valve guide remover ...

  • Page 293: Valves and Valve Springs

    Valves and valve springs 5-44 6. Measure: • valve stem runout out of specification → replace the valve. Note: • when installing a new valve, always replace the valve guide. • if the valve is removed or replaced, always re- place the valve stem seal. Eas24300 checking the valve seats the following pr...

  • Page 294: Valves and Valve Springs

    Valves and valve springs 5-45 caution: eca13790 do not let the lapping compound enter the gap between the valve stem and the valve guide. B. Apply molybdenum disulfide oil onto the valve stem. C. Install the valve into the cylinder head. D. Turn the valve until the valve face and valve seat are even...

  • Page 295: Valves and Valve Springs

    Valves and valve springs 5-46 2. Measure: • compressed valve spring force “a” out of specification → replace the valve spring. 3. Measure: • valve spring tilt “a” out of specification → replace the valve spring. Eas24340 installing the valves the following procedure applies to all of the valves and ...

  • Page 296: Valves and Valve Springs

    Valves and valve springs 5-47 note: • make sure each valve is installed in its original place. • install the valve springs with the larger pitch “a” facing up. 4. Install: • valve cotters note: install the valve cotters by compressing the valve springs with the valve spring compressor set “1”. 5. To...

  • Page 297: Cylinders and Pistons

    Cylinders and pistons 5-48 eas24360 cylinders and pistons removing the cylinders and pistons order job/parts to remove q’ty remarks cylinder heads refer to “cylinder heads” on page 5-36. 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 to...

  • Page 298: Cylinders and Pistons

    Cylinders and pistons 5-49 eas24380 removing the piston 1. Remove: • piston pin clips “1” • piston pin “2” • piston “3” caution: eca13810 do not use a hammer to drive the piston pin out. Note: • before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston p...

  • Page 299: Cylinders and Pistons

    Cylinders and pistons 5-50 b. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. C. Measure piston skirt diameter d “a” with the micrometer. D. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cy...

  • Page 300: Cylinders and Pistons

    Cylinders and pistons 5-51 3. Measure: • piston ring end gap out of specification → replace the piston ring. Note: the oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Eas24440 checking the piston pins the following pro...

  • Page 301: Cylinders and Pistons

    Cylinders and pistons 5-52 note: be sure to install the piston rings so that the manufacturer’s marks or numbers face up. 2. Install: • piston “1” • piston pin “2” • piston pin clips “3” note: • apply engine oil onto the piston pin. • make sure the arrow mark “a” on the piston fac- es towards the fr...

  • Page 302: Clutch

    Clutch 5-53 eas25060 clutch removing the clutch cover order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Left side cover refer to “general chassis” on page 4-1. Horn 1/canister refer to “throttle bodies” on page 6-7. For california only fuel tan...

  • Page 303: Clutch

    Clutch 5-54 6 clutch cover 1 7 clutch cover gasket 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 • ib) new (11) 5 4 (5) t r . . ...

  • Page 304: Clutch

    Clutch 5-55 removing the crankshaft position sensor order job/parts to remove q’ty 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 proce- dure. 5 6 5...

  • Page 305: Clutch

    Clutch 5-56 removing the clutch order job/parts to remove q’ty remarks 1 clutch spring plate retainer 1 2 clutch spring plate 1 3 clutch spring plate seat 1 4 pressure plate 1 5 short clutch push rod 1 6 friction plate 1 1 inside diameter: 124 mm (4.88 in) 7 clutch plate 9 8 friction plate 2 9 9 clu...

  • Page 306: Clutch

    Clutch 5-57 18 thrust washer 1 1 19 clutch housing 1 20 circlip 1 21 washer 1 22 oil pump drive gear 1 23 dowel pin 2 24 bearing 1 25 collar 1 26 thrust washer 2 1 27 ball 1 28 long push rod 1 29 spacer 1 30 crankshaft position sensor rotor 1 31 primary drive gear 1 32 straight key 1 removing the cl...

  • Page 307: Clutch

    Clutch 5-58 a: for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) b: for xv19cs(c)/ xv19c(c) 33 washer 1 for installation, reverse the removal 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 ...

  • Page 308: Clutch

    Clutch 5-59 removing the left balancer order job/parts to remove q’ty remarks 1 left balancer idle gear shaft holder 1 2 dowel pin 2 3 o-ring 2 4 left balancer idle gear 1 5 left balancer idle gear shaft 1 6 left balancer drive gear 1 7 straight key 1 8 left balancer driven gear 1 9 left balancer we...

  • Page 309: Clutch

    Clutch 5-60 removing the clutch master cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-15. 1 left rearview mirror 1 2 clutch master cylinder reservoir cap 1 3 clutch master cylinder reservoir diaphragm holder 1 4 clutch ma...

  • Page 310: Clutch

    Clutch 5-61 disassembling the clutch master cylinder 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 the disassembly pro- cedure. 3 4 5 6 2 1 new new s.

  • Page 311: Clutch

    Clutch 5-62 * xv19cs(c)/ xv19c(c) removing the clutch release cylinder order job/parts to remove q’ty remarks clutch fluid drain. Refer to “bleeding the hydraulic clutch system” on page 3-15. Muffler/exhaust pipes refer to “engine removal” on page 5-1. 1 clutch pipe union bolt cap 1 2 clutch pipe un...

  • Page 312: Clutch

    Clutch 5-63 disassembling the clutch release cylinder order job/parts to remove 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, reverse the disassembly ...

  • Page 313: Clutch

    Clutch 5-64 eas25080 removing the clutch 1. Loosen: • clutch boss nut “1” note: while holding the clutch boss “2” with the univer- sal clutch holder “3”, loosen the clutch boss nut. 2. Remove: • clutch boss nut “1” • conical spring washer “2” • washer “3” • clutch boss assembly “4” note: there is a ...

  • Page 314: Clutch

    Clutch 5-65 eas25100 checking the friction plates the following procedure applies to all of the fric- tion plates. 1. Check: • friction plate damage/wear → replace the friction plates as a set. 2. Measure: • friction plate thickness out of specification → replace the friction plates as a set. Note: ...

  • Page 315: Clutch

    Clutch 5-66 2. Check: • clutch spring plate seat damage → replace. Eas25150 checking the clutch housing 1. Check: • clutch housing dogs damage/pitting/wear → deburr the clutch housing dogs or replace the clutch housing. Note: pitting on the clutch housing dogs will cause er- ratic clutch operation. ...

  • Page 316: Clutch

    Clutch 5-67 • left balancer idle gear burrs/chips/roughness/wear → replace the defective part(s). 2. Measure: • left balancer driven gear inside diameter “a” out of specification → replace. 3. Measure: • left balancer driven gear housing outside di- ameter “a” out of specification → replace. 4. Calc...

  • Page 317: Clutch

    Clutch 5-68 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Install: • generator rotor refer to “installing the generator” on page 5-80. 5. Install: • left balancer drive gear “1” • left balancer idle gear “2” • left balancer driven gear “3” note: • align the punch mark “a” on the left balancer...

  • Page 318: Clutch

    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 ...

  • Page 319: Clutch

    Clutch 5-70 6. Install: • clutch spring plate • clutch spring plate retainer note: tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern. 7. Apply: • sealant (onto the crankshaft position sensor lead grommet) 8. Install: • shift arm “1” note: install the shift arm “1” ...

  • Page 320: Clutch

    Clutch 5-71 • clutch master cylinder reservoir diaphragm damage/wear → replace. 4. Check: • clutch hose cracks/damage/wear → replace. Eas25300 assembling the clutch master cylinder warning ew1d71010 • before installation, all internal clutch com- ponents must be cleaned and lubricated with clean or ...

  • Page 321: Clutch

    Clutch 5-72 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 fluid that is already in the system. Mixing clutch flu- ids may result in a harmful c...

  • Page 322: Clutch

    Clutch 5-73 eas25340 assembling the clutch release cylinder warning ew1d71006 • before installation, all internal clutch com- ponents must be cleaned and lubricated with clean or new clutch fluid. • never use solvents on internal clutch com- ponents as they will cause the piston seal to swell and di...

  • Page 323: Clutch

    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: Shift Shaft

    Shift shaft 5-75 eas25410 shift shaft removing the shift shaft and stopper lever order job/parts to remove q’ty remarks clutch housing 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 spr...

  • Page 325: Shift Shaft

    Shift shaft 5-76 eas25420 checking the shift shaft 1. Check: • shift shaft bends/damage/wear → replace. • shift shaft spring damage/wear → replace. Eas25430 checking the stopper lever 1. Check: • stopper lever bends/damage → replace. Roller turns roughly → replace the stopper lever. • stopper lever ...

  • Page 326: Generator and Starter Clutch

    Generator and starter clutch 5-77 eas24480 generator and starter clutch removing the stator coil order job/parts to remove q’ty remarks engine oil drain. Refer to “changing the engine oil” on page 3-11. Muffler/exhaust pipes refer to “engine removal” on page 5-1. Lead cover refer to “belt drive” on ...

  • Page 327: Generator and Starter Clutch

    Generator and starter clutch 5-78 removing the generator rotor order job/parts to remove q’ty remarks 1 torque limiter 1 2 starter clutch 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...

  • Page 328: Generator and Starter Clutch

    Generator and starter clutch 5-79 eas24490 removing the generator 1. Remove: • generator rotor bolt “1” • washer note: while holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. 2. Remove: • generator rotor “1” (with the rotor puller “2”) • woodruff key eas245...

  • Page 329: Generator and Starter Clutch

    Generator and starter clutch 5-80 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et1d71020 checking the torque limiter 1. Check: • torque limiter damage/wear → replace. Note: do not disassemble the torque limiter. Eas24600 installing the starter clutch 1. Install: • starter clutch note: while hol...

  • Page 330: Generator and Starter Clutch

    Generator and starter clutch 5-81.

  • Page 331: Electric Starter

    Electric starter 5-82 eas24780 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 . . 10 nm (1.0 m • kg, 7.2 ft • ib).

  • Page 332: Electric Starter

    Electric starter 5-83 disassembling the starter motor order job/parts to remove q’ty remarks 1 starter motor front cover 1 2 bearing 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 gask...

  • Page 333: Electric Starter

    Electric starter 5-84 eas24790 checking the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter “a” out of specification → replace the starter motor. 3. Measure: • mica undercut “a” out of specification → scrape the mica to the proper measurem...

  • Page 334: Electric Starter

    Electric starter 5-85 7. Check: • gear teeth damage/wear → replace the gear. 8. Check: • bearings • oil seal damage/wear → replace the defective part(s). Eas24800 assembling the starter motor 1. Install: • starter motor yoke “1” note: align the projection “a” on the brush holder with the slot “b” in...

  • Page 335: Transfer Gear Case

    Transfer gear case 5-86 eas25460 transfer gear case removing the middle driven shaft order job/parts to remove q’ty remarks rider seat/right side cover refer to “general chassis” on page 4-1. Engine oil drain. Refer to “changing the engine oil” on page 3-11. Transfer gear oil drain. Refer to “changi...

  • Page 336: Transfer Gear Case

    Transfer gear case 5-87 8 oil strainer 1 9 gasket 1 10 conical spring washer 1 11 primary chain 1 12 middle drive gear 1 13 middle driven shaft 1 for installation, reverse the removal proce- dure. Removing the middle driven shaft order job/parts to remove q’ty remarks 8 6 7 1 2 3 12 10 5 5 4 9 (7) (...

  • Page 337: Transfer Gear Case

    Transfer gear case 5-88 disassembling the transfer gear oil pump order job/parts to remove q’ty remarks 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 housing ...

  • Page 338: Transfer Gear Case

    Transfer gear case 5-89 removing the transfer gear case order job/parts to remove q’ty remarks horn 2 connector disconnect. Refer to “engine removal” on page 5-1. Battery box refer to “general chassis” on page 4-1. Sub-fuel tank refer to “fuel tank” on page 6-1. 1 oil tank breather hose 1 disconnect...

  • Page 339: Transfer Gear Case

    Transfer gear case 5-90 disassembling the oil tank order job/parts to remove q’ty remarks 1 sub-fuel tank bracket 1 2 oil tank 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 . ...

  • Page 340: Transfer Gear Case

    Transfer gear case 5-91 eas25470 removing the middle driven shaft note: loosen the middle drive gear nut before remove the drive pulley. 1. Install: • right rider footrest assembly refer to “engine removal” on page 5-1. 2. Loosen: • middle drive gear nut “1” note: when loosening the middle drive gea...

  • Page 341: Transfer Gear Case

    Transfer gear case 5-92 3. Check: • transfer gear oil pump operation rough movement → repeat steps (1) and (2) or replace the defective part(s). Eas25510 checking the oil pipes 1. Check: • oil pipes damage → replace. Eas25520 assembling the transfer gear oil pump 1. Lubricate: • transfer gear oil pu...

  • Page 342: Transfer Gear Case

    Transfer gear case 5-93 • install the middle driven shaft, middle drive gear and primary chain at the same time. • align the splines on the middle drive gear with the splines on the drive axle. • temporarily install the drive pulley nut onto the middle driven shaft. 3. Install: • conical spring wash...

  • Page 343: Crankcase

    Crankcase 5-94 eas25540 crankcase separating the crankcase order job/parts to remove q’ty remarks engine refer to “engine removal” on page 5-1. Camshafts refer to “camshafts” on page 5-17. Pistons refer to “cylinders and pistons” on page 5-48. Left balancer driven gear housing refer to “clutch” on p...

  • Page 344: Crankcase

    Crankcase 5-95 10 joint pipe 1 11 oil pipe 1 “r” mark 12 oil pipe 1 “f” mark 13 right crankcase 1 for installation, reverse the removal proce- dure. Separating the crankcase order job/parts to remove 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 . ....

  • Page 345: Crankcase

    Crankcase 5-96 a: for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) b: for xv19cs(c)/ xv19c(c) removing the oil seals and bearings order job/parts to remove q’ty remarks oil pump refer to “oil pump” on page 5-100. Crankshaft refer to “crankshaft” on page 5-106. Transmission refer to “transmission” on p...

  • Page 346: Crankcase

    Crankcase 5-97 eas25570 disassembling the crankcase 1. Remove: • crankcase bolts note: • loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • loosen the bolts in decreasing numerical order (refer to the numbers i...

  • Page 347: Crankcase

    Crankcase 5-98 et1d71034 installing the bearing retainers 1. Install: • bearing retainers “1” note: • apply locking agent (loctite®) to the threads of the bearing retainer bolts. • stake the bearing retainer bolts “2”. Eas25690 assembling the crankcase 1. Apply: • sealant (onto the crankcase mating ...

  • Page 348: Crankcase

    Crankcase 5-99 5. Apply: • engine 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 17 18 12 10 9 22 23 13 11 24 b.

  • Page 349: Oil Pump

    Oil pump 5-100 eas24910 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 . . 24 nm (2.4 m • kg, 17 ft • ib).

  • Page 350: Oil Pump

    Oil pump 5-101 disassembling the oil pump order job/parts to remove q’ty remarks 1 oil pump housing cover 1 1 2 oil scavenging pump outer rotor 1 1 3 oil scavenging pump inner rotor 1 1 4 pin 1 5 oil pump housing 1 1 6 oil strainer 1 7 pin 2 8 ball spring 1 9 oil scavenging pump outer rotor 2 1 10 o...

  • Page 351: Oil Pump

    Oil pump 5-102 18 oil pump shaft 1 19 oil seal 1 20 circlip 1 21 oil seal 1 22 ball 1 23 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 (...

  • Page 352: Oil Pump

    Oil pump 5-103 eas24960 checking the oil pump 1. Check: • oil pump housing • oil pump housing cover cracks/damage/wear → replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance “a” • outer-rotor-to-oil-pump-housing clearance “b” • oil-pump-housing-to-inner-rotor-and-o...

  • Page 353: Oil Pump

    Oil pump 5-104 2. Measure: • ball spring force • relief valve spring force out of specification → replace the defective part(s). Eas24990 checking the oil strainer 1. Check: • oil strainer “1” damage → replace. Contaminants → clean with solvent. Eas25000 assembling the oil pump 1. Lubricate: • inner...

  • Page 354: Oil Pump

    Oil pump 5-105 3. Check: • oil pump operation refer to “checking the oil pump” on page 5-103. Eas25020 installing the oil pump 1. Install: • oil pump assembly “1” 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 f...

  • Page 355: Crankshaft

    Crankshaft 5-106 eas25960 crankshaft removing the crankshaft order 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 upper bearing 2 for installation...

  • Page 356: Crankshaft

    Crankshaft 5-107 eas26010 removing the connecting rods 1. Remove: • connecting rod caps “1” • connecting rods • big end bearings note: identify the position of each big end bearing so that it can be reinstalled in its original place. Eas26090 checking the crankshaft and connecting rods 1. Measure: •...

  • Page 357: Crankshaft

    Crankshaft 5-108 d. Assemble the connecting rod halves. Note: • do not move the connecting rod or crankshaft until the clearance measurement has been completed. • lubricate the bolts threads with molybdenum disulfide grease. • make sure the projection “c” on the connecting rod faces towards the left...

  • Page 358: Crankshaft

    Crankshaft 5-109 ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 4. Select: • big end bearings (“p 1 ”–“p 2 ”) note: • the numbers “a” stamped into the crankshaft web and the numbers “b” on the connecting rods are used to determine the replacement big end bearing sizes. • “p 1 ”–“p 2 ” refer to th...

  • Page 359: Crankshaft

    Crankshaft 5-110 eas26150 installing the connecting rods 1. Lubricate: • bolt threads (with the recommended lubricant) 2. Lubricate: • crankshaft pins • big end bearings • connecting rod inner surface (with the recommended lubricant) 3. Install: • big end bearings • connecting rods • connecting rod ...

  • Page 360: Crankshaft

    Crankshaft 5-111 c. Tighten the connecting rod bolts further to reach the specified angle 125–135°. Warning ew1d71011 when a bolt is tightened more than the spec- ified angle, do not loosen and then retighten it. Replace the bolt with a new one and perform the procedure again. Caution: ec1d71001 • d...

  • Page 361: Transmission

    Transmission 5-112 eas26240 transmission removing the transmission, shift drum assembly, and shift forks order 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 assem...

  • Page 362: Transmission

    Transmission 5-113 disassembling the main axle assembly order job/parts to remove q’ty remarks 1 2nd 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: Transmission

    Transmission 5-114 disassembling the drive axle assembly order job/parts to remove q’ty 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 1 12 5th wheel...

  • Page 364: Transmission

    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: Transmission

    Transmission 5-116 eas26260 checking the shift forks the following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower “1” • shift fork pawl “2” bends/damage/scoring/wear → replace the shift fork. 2. Check: • shift fork guide bar roll the shift fork guide bar on a flat s...

  • Page 366: Transmission

    Transmission 5-117 3. Check: • transmission gears blue discoloration/pitting/wear → replace the defective gear(s). • transmission gear dogs cracks/damage/rounded edges → replace the defective gear(s). 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) incorrect ...

  • Page 367: Transmission

    Transmission 5-118 note: the embossed marks “1d7” on the shift forks should face towards the left side of the engine. 2. Check: • transmission rough movement → repair. Note: • apply engine oil to each gear and bearing thor- oughly. • before assembling the crankcase, make sure that the transmission i...

  • Page 368: Transmission

    Transmission 5-119.

  • Page 369: Fuel System

    6 fuel system fuel tank..................................................................................................... 6-1 removing the fuel tank .................................................................. 6-4 removing the fuel pump .........................................................

  • Page 370: Fuel Tank

    Fuel tank 6-1 eas26620 fuel tank removing the fuel tank order job/parts to remove q’ty remarks rider seat/rider seat bracket refer to “general chassis” on page 4-1. 1 meter cover 1 2 meter assembly coupler 3 disconnect. For xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) 3 meter assembly coupler 2 discon...

  • Page 371: Fuel Tank

    Fuel tank 6-2 a: for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c) b: for xv19cs(c)/ xv19c(c) 10 fuel sender 1 for installation, 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 • ...

  • Page 372: Fuel Tank

    Fuel tank 6-3 removing the fuel pump and sub-fuel tank order job/parts to remove q’ty remarks rider seat/rider seat bracket refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. 1 fuel pump coupler 1 disconnect. 2 fuel hose connector cover 1 3 fuel outlet hose 1 disconn...

  • Page 373: Fuel Tank

    Fuel tank 6-4 eas26630 removing the fuel tank 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel tank caution: ec1d71021 although the fuel has been removed from the fuel tank, be careful when removing the fuel hoses, since there may be fuel remain- ing in t...

  • Page 374: Fuel Tank

    Fuel tank 6-5 caution: ec1d71022 • be sure to disconnect the fuel outlet hose by hand. Do not forcefully disconnect the hose with tools. • although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in them. Note: • remove the fu...

  • Page 375: Fuel Tank

    Fuel tank 6-6 b. Remove the fuel hose joint caps. C. Connect the fuel hose (fuel hose joint to fuel pump) and air vent hose (fuel pump to fuel hose joint). D. Turn the screws “1” counterclockwise. Note: turn the screws until they contact the clips “a”. E. Install the fuel hose joint caps. Note: inst...

  • Page 376: Throttle Bodies

    Throttle bodies 6-7 eas26970 throttle bodies removing the rollover valves (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks 1 horn 1 connector 2 for california only disconnect. 2 horn 1 1 for california only 3 fuel tank breather hose 1 4 canister purge hose 1 fo...

  • Page 377: Throttle Bodies

    Throttle bodies 6-8 removing the rollover valves (for xv19cs/ xv19c) order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. Air filter case 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 val...

  • Page 378: Throttle Bodies

    Throttle bodies 6-9 removing the rollover valves (for california only) (for xv19csc/ xv19cc) order job/parts to remove q’ty remarks fuel tank refer to “fuel tank” on page 6-1. Air filter case refer to “general chassis” on page 4-1. 1 horn 1 connector 2 disconnect. 2 horn 1 1 3 pressure regulator cov...

  • Page 379: Throttle Bodies

    Throttle bodies 6-10 removing the pressure regulator (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) order job/parts to remove q’ty remarks 1 pressure regulator cover 1 2 fuel hose (intake manifold assembly to pres- sure regulator) 1 3 air filter case breather hose 1 1 4 air filter case breather ho...

  • Page 380: Throttle Bodies

    Throttle bodies 6-11 removing the left ignition coils and pressure regulator (for xv19cs(c)/ xv19c(c)) order job/parts to remove q’ty remarks rollover valves refer to “throttle bodies” on page 6-7. 1 ignition coil connector 4 disconnect. 2 cylinder-#2 left ignition coil 1 3 cylinder-#1 left ignition...

  • Page 381: Throttle Bodies

    Throttle bodies 6-12 removing the throttle bodies order job/parts to remove q’ty remarks rider seat/rider seat bracket refer to “general chassis” on page 4-1. Fuel tank refer to “fuel tank” on page 6-1. Air filter case refer to “general chassis” on page 4-1. Cylinder-#1 ignition coil cover refer to ...

  • Page 382: Throttle Bodies

    Throttle bodies 6-13 removing the intake manifolds order job/parts to remove q’ty remarks 1 engine temperature sensor coupler 1 disconnect. 2 sub-wire harness 2 coupler 2 disconnect. 3 fuel outlet hose 1 disconnect. 4 fuel hose (intake manifold assembly to pres- sure regulator) 1 5 cylinder-#2 isc (...

  • Page 383: Throttle Bodies

    Throttle bodies 6-14 disassembling the intake manifolds order job/parts to remove q’ty remarks 1 cylinder-#1 injector coupler 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 t...

  • Page 384: Throttle Bodies

    Throttle bodies 6-15 et1d71026 removing the fuel hose 1. Disconnect: • fuel hose (intake manifold assembly to pres- sure regulator) caution: ec1d71014 although the fuel has been removed from the fuel tank be careful when removing the fuel hose, since there may be fuel remaining in it. Note: • to rem...

  • Page 385: Throttle Bodies

    Throttle bodies 6-16 f. Start the engine. G. Measure the fuel pressure. H. Use the vacuum/pressure pump gauge set to adjust the fuel pressure in relation to the vac- uum pressure as described below. Note: the vacuum pressure should not exceed 100 kpa (760 mmhg). Faulty → replace the pressure regulat...

  • Page 386: Throttle Bodies

    Throttle bodies 6-17 note: install the fuel pipe “1” so that it contacts the pro- jections “a” on the injector joints. Et1d71027 installing the fuel hose 1. Connect: • fuel hose (intake manifold assembly to pres- sure regulator) caution: ec1d71015 when installing the fuel hose, make sure that it is ...

  • Page 387

    Isc (idle speed control) unit 6-18 et1d71009 isc (idle speed control) unit removing the isc (idle speed control) unit order job/parts to remove q’ty remarks front cylinder head refer to “cylinder heads” on page 5-36. 1 sub-wire harness 4 1 2 sub-wire harness 3 1 3 cylinder-#2 isc (idle speed control...

  • 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: Electrical System

    7 electrical system ignition system ......................................................................................... 7-1 circuit diagram .................................................................................. 7-1 engine stopping due to sidestand operation ....................... ...

  • Page 390

    Electrical components...................................................................... 7-67 checking the switches ................................................................. 7-71 checking the bulbs and bulb sockets ................................... 7-74 checking the fuses .................

  • Page 392: Ignition System

    Ignition system 7-1 eas27090 ignition system eas27110 circuit diagram w w w r r /g b (gra y) on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l r l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /y l /ys b l /g b (...

  • Page 393: Ignition System

    Ignition system 7-2 3. Main switch 4. Main fuse 6. Battery 11.Relay unit 14.Neutral switch 16.Sidestand switch 19.Crankshaft 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...

  • Page 394: Ignition System

    Ignition system 7-3 et1d71043 engine stopping due to sidestand operation when the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ecu when both the neutral switch...

  • Page 395: Ignition System

    Ignition system 7-4 eas27140 troubleshooting the ignition system fails to operate (no spark or intermittent spark). Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rider seat bracket assembly 4. Fuel tank 5. Air filter case 6. Headlight assembly 7. Exh...

  • Page 396: Ignition System

    Ignition system 7-5 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 7. Check the crankshaft position sen- sor. Refer to “checking the crank- shaft position sensor” on page 7-84. Replace the crankshaft position sensor. 8. Check the main switch. Refer to “checking the s...

  • Page 397: Ignition System

    Ignition system 7-6.

  • Page 398: Electric Starting System

    Electric starting system 7-7 eas27160 electric starting system eas27170 circuit diagram w w w r r /g b (gra y) on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l r l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /...

  • Page 399: Electric Starting System

    Electric starting system 7-8 3. Main switch 4. Main fuse 6. Battery 8. Starter relay 9. Starter motor 10.Diode 1 (for xv19s(c)/ 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...

  • Page 400: Electric Starting System

    Electric starting system 7-9 eas27180 starting circuit cut-off system operation if the engine stop switch is set to “ ” and the main switch is turned “on” (both switch circuits are closed), the starter motor can only operate if at least one of the following conditions is met: • the transmission is i...

  • Page 401: Electric Starting System

    Electric starting system 7-10 a. When the transmission is in neutral b. When the sidestand is up and the clutch lever is pulled to the handlebar 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Diode 2 (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 7. Relay unit (st...

  • Page 402: Electric Starting System

    Electric starting system 7-11 eas27190 troubleshooting the starter motor fails to turn. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Headlight assembly ng → ok ↓ ng → ok ↓ ok → ng ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuses. (main, ...

  • Page 403: Electric Starting System

    Electric starting system 7-12 ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 8. Check the diode 2. (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) refer to “checking the di- odes” on page 7-81. Replace the diode 2. 9. Check the starter relay. Refer to “che...

  • Page 404: Charging System

    Charging system 7-13 eas27200 charging system eas27210 circuit diagram w w w r r /g b on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /y l /ys b l /g b (blue) l /...

  • Page 405: Charging System

    Charging system 7-14 1. Ac magneto 2. Rectifier/regulator 4. Main fuse 6. Battery.

  • Page 406: Charging System

    Charging system 7-15 eas27220 troubleshooting the battery is not being charged. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Rectifier/regulator cover 3. Lead cover ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ 1. Check the fuse. (main) refer to “checking the fu...

  • Page 407: Charging System

    Charging system 7-16.

  • Page 408: Lighting System

    Lighting system 7-17 eas27240 lighting system eas27250 circuit diagram w w w r r /g b (gra y) on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l r l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /y l /ys b l /g b ...

  • Page 409: Lighting System

    Lighting system 7-18 3. Main switch 4. Main fuse 6. Battery 27.Ecu (electronic control unit) 44.Meter light 47.High beam indicator light 52.Headlight relay 55.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 64.Headlight (high beam) 65.Headlight (low b...

  • Page 410: Lighting System

    Lighting system 7-19 eas27260 troubleshooting any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light, taillight, license light, position light, meter light or accessory light (option). Note: • before troubleshooting, remove the following part(s): 1...

  • Page 411: Lighting System

    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: Signaling System

    Signaling system 7-21 eas27270 signaling system eas27280 circuit diagram w w w r r /g b (gra y) on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l r l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /y l /ys b l /g ...

  • Page 413: Signaling System

    Signaling system 7-22 3. Main switch 4. Main fuse 5. Backup fuse (odometer and clock) 6. Battery 11.Relay unit 14.Neutral switch 18.Fuel sender (fuel pump) 24.Speed sensor 27.Ecu (electronic control unit) 39.Neutral indicator light 40.Multi-function meter 43.Fuel level warning light 45.Left turn sig...

  • Page 414: Signaling System

    Signaling system 7-23 eas27290 troubleshooting • any of the following fail to light: turn signal light, brake light or an indicator light. • the horn fails to sound. • the fuel level gauge fails to operate. • the speedometer fails to operate. Note: • before troubleshooting, remove the following part...

  • Page 415: Signaling System

    Signaling system 7-24 ng → ok ↓ ng → ok ↓ the tail/brake light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the turn signal light, turn signal indicator light or both fail to blink. Ng → ok ↓ ng → ok ↓ ng → ok ↓ 2. Check the horns. Refer to “checking the horns” on page 7-86. Replace the horn(s). ...

  • Page 416: Signaling System

    Signaling system 7-25 ng → ok ↓ the neutral indicator light fails to come on. Ng → ok ↓ ng → ok ↓ ng → ok ↓ the fuel level gauge fails to operate. Ng → ok ↓ ng → ok ↓ the fuel level warning light fails to come on. Ng → ok ↓ 4. Check the entire signaling system wiring. Refer to “circuit diagram” on p...

  • Page 417: Signaling System

    Signaling system 7-26 ng → ok ↓ ng → ok ↓ the speedometer fails to operate. Ng → ok ↓ ng → ok ↓ 2. Check the fuel sender (fuel pump). Refer to “checking the fuel sender (fuel pump)” on page 7-88. Replace the fuel pump assembly. 3. Check the entire signaling system wiring. Refer to “circuit diagram” ...

  • Page 418: Fuel Injection System

    Fuel injection system 7-27 eas27330 fuel injection system eas27340 circuit diagram w w w r r /g b (gra y) on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l r l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /y l /...

  • Page 419: Fuel Injection System

    Fuel injection system 7-28 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 12.Starting circuit cut-off relay 13.Fuel pump relay 14.Neutral switch 15.Diode 2 (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 16.Sidestand switch 17.Fuel pump 19.Crankshaft position sen...

  • Page 420: Fuel Injection System

    Fuel injection system 7-29 eas27350 ecu self-diagnostic function the ecu is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute ch...

  • Page 421: Fuel Injection System

    Fuel injection system 7-30 eas27380 self-diagnostic function table if the ecu detects an abnormal signal from a sensor while the vehicle is being driven, the ecu illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the ...

  • Page 422: Fuel Injection System

    Fuel injection system 7-31 33 cylinder-#1 left or right ignition coil (faulty ignition) malfunction detected in the prima- ry wire of the cylinder-#1 left or right ignition coil. Able (depending on the number of faulty cylin- ders) able (depending on the number of faulty cylin- ders) 34 cylinder-#2 ...

  • Page 423: Fuel Injection System

    Fuel injection system 7-32 communication error with the meter eas27400 troubleshooting method the engine operation is not normal and the engine trouble warning light comes on. 1. Check: • fault code number ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Check the fault code number displayed on ...

  • Page 424: Fuel Injection System

    Fuel injection system 7-33 5. Erase the malfunction history in the diagnos- tic mode. Refer to “sensor operation table (diagnostic code no. 62)”. Note: turning the main switch to “off” will not erase the malfunction history. The engine operation is not normal but the engine trouble warning light doe...

  • Page 425: Fuel Injection System

    Fuel injection system 7-34 7. Verify the operation of the sensor or actuator. • sensor operation the data representing the operating conditions of the sensor appears on the odometer/trip meter/fu- el reserve trip meter/clock lcd. • actuator operation set the engine stop switch to “ ” to operate the ...

  • Page 426: Fuel Injection System

    Fuel injection system 7-35 19 a break or disconnection of the blue/black lead of the ecu is detected. • open circuit in wire harness (ecu coupler). • malfunction in ecu. 20 22 air temperature sensor: open or short circuit detect- ed. • open or short circuit in wire harness. • defective air temperatu...

  • Page 427: Fuel Injection System

    Fuel injection system 7-36 36 malfunction detected in the primary wire of the cylin- der-#2 left or right ignition coil. • open or short circuit in wire sub lead. • open or short circuit in wire harness. • malfunction in cylinder-#2 left or right igni- tion coil. • malfunction in ecu. • malfunction ...

  • Page 428: Fuel Injection System

    Fuel injection system 7-37 sensor operation table er-1 no signals are received from the ecu. • open or short circuit in wire harness. • malfunction in meter. • malfunction in ecu. • defective wire connection of the ecu cou- pler. — er-2 no signals are received from the ecu within the specified durat...

  • Page 429: Fuel Injection System

    Fuel injection system 7-38 09 fuel system voltage (battery voltage) approximately 12.0 set the engine stop switch to “ ”, and then compare with the actually measured battery voltage. (if the bat- tery voltage is lower, per- form recharging.) 11 engine temperature displays the engine tempera- ture. C...

  • Page 430: Fuel Injection System

    Fuel injection system 7-39 actuator operation table 70 control number 0–255 — diag- nostic code no. Item meter display checking method diag- nostic code no. Item actuation checking method 30 cylinder-#1 left or right ig- nition coil actuates the cylinder-#1 left or right ignition coil five times at ...

  • Page 431: Fuel Injection System

    Fuel injection system 7-40 eas27460 troubleshooting details this section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunc...

  • Page 432: Fuel Injection System

    Fuel injection system 7-41 fault code no. 12 symptom no normal signals are received from the crankshaft posi- tion sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of crankshaft posi- tion sensor. Check for l...

  • Page 433: Fuel Injection System

    Fuel injection system 7-42 fault code no. 13 symptom cylinder-#1 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code no. 03 cylinder-#1 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder...

  • Page 434: Fuel Injection System

    Fuel injection system 7-43 fault code no. 14 symptom cylinder-#1 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code no. 03 cylinder-#1 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 cy...

  • Page 435: Fuel Injection System

    Fuel injection system 7-44 fault code no. 15 symptom throttle position sensor: open or short circuit detected. Diagnostic code no. 01 throttle position sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed condition of throttle position sensor. • c...

  • Page 436: Fuel Injection System

    Fuel injection system 7-45 fault code no. 17 symptom exup servo motor circuit: open or short circuit detected. Diagnostic code no. 53 exup servo motor order item/components and probable cause check or maintenance job reinstatement method 1 connections • exup servo motor coupler • main wire harness e...

  • Page 437: Fuel Injection System

    Fuel injection system 7-46 fault code no. 19 symptom a break or disconnection of the blue/black lead of the ecu is detected. Diagnostic code no. 20 sidestand switch order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • ...

  • Page 438: Fuel Injection System

    Fuel injection system 7-47 fault code no. 24 symptom no normal signal is received from the o 2 sensor. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 installed state of o 2 sensor. Check for looseness or pinching. Starting the en- gin...

  • Page 439: Fuel Injection System

    Fuel injection system 7-48 fault code no. 25 symptom cylinder-#2 intake air pressure sensor: open or short cir- cuit detected. Diagnostic code no. 04 cylinder-#2 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • cylinder...

  • Page 440: Fuel Injection System

    Fuel injection system 7-49 fault code no. 26 symptom cylinder-#2 intake air pressure sensor: hose system mal- function (clogged or detached hose). Diagnostic code no. 04 cylinder-#2 intake air pressure sensor order item/components and probable cause check or maintenance job reinstatement method 1 cy...

  • Page 441: Fuel Injection System

    Fuel injection system 7-50 fault code no. 28 symptom engine temperature sensor: open or short circuit detect- ed. Diagnostic code no. 11 engine temperature sensor order item/components and probable cause check or maintenance job reinstatement method 1 installed state of engine temperature sensor. Ch...

  • Page 442: Fuel Injection System

    Fuel injection system 7-51 fault code no. 33 symptom malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code no. 30, 32 cylinder-#1 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 443: Fuel Injection System

    Fuel injection system 7-52 fault code no. 34 symptom malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code no. 31, 33 cylinder-#2 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 444: Fuel Injection System

    Fuel injection system 7-53 fault code no. 35 symptom malfunction detected in the primary wire of the cylinder-#1 left or right ignition coil. Diagnostic code no. 30, 32 cylinder-#1 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 445: Fuel Injection System

    Fuel injection system 7-54 fault code no. 36 symptom malfunction detected in the primary wire of the cylinder-#2 left or right ignition coil. Diagnostic code no. 31, 33 cylinder-#2 left or right ignition coil order item/components and probable cause check or maintenance job reinstatement method 1 co...

  • Page 446: Fuel Injection System

    Fuel injection system 7-55 fault code no. 37 symptom engine speed is high when the engine is idling. Diagnostic code no. 54 isc valve order item/components and probable cause check or maintenance job reinstatement method 1 ecu fuse is blown. (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) • check t...

  • Page 447: Fuel Injection System

    Fuel injection system 7-56 fault code no. 41 symptom lean angle sensor: open or short circuit detected. Diagnostic code no. 08 lean angle sensor order item/components and probable cause check or maintenance job reinstatement method 1 connections • lean angle sensor coupler • main wire harness ecu co...

  • Page 448: Fuel Injection System

    Fuel injection system 7-57 fault code no. 42 symptom a. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code no. A 07 speed sensor b 21 neutral switch order item/components and probable cause check or maintenance job reinstatement m...

  • Page 449: Fuel Injection System

    Fuel injection system 7-58 b-1 connections • neutral switch 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 se- curely. Starting the en- gine,...

  • Page 450: Fuel Injection System

    Fuel injection system 7-59 fault code no. 43 symptom the ecu is unable to monitor the battery voltage (an open or short circuit in the line to the ecu). Diagnostic code no. 09 fuel system voltage order item/components and probable cause check or maintenance job reinstatement method 1 connections • r...

  • Page 451: Fuel Injection System

    Fuel injection system 7-60 fault code no. 46 symptom power supply to the fuel injection system is not normal. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • check the coupler for any pins ...

  • Page 452: Fuel Injection System

    Fuel injection system 7-61 fault code no. Er-1 symptom no signals are received from the ecu. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly coupler • check...

  • Page 453: Fuel Injection System

    Fuel injection system 7-62 fault code no. Er-3 symptom data from the ecu cannot be received correctly. Diagnostic code no. — — order item/components and probable cause check or maintenance job reinstatement method 1 connections • main wire harness ecu coupler • main wire harness meter assembly coupl...

  • Page 454: Fuel Pump System

    Fuel pump system 7-63 eas27550 fuel pump system eas27560 circuit diagram w w w r r /g b (gra y) on off r br r br /l r l /y br /l l /b r r r r r b b b r r r b r /y l b r /wr /w r /y r /y r /w r /w r /l r l /y l /r r /y l /w sb /w sb l l b /y r r /l l /gs b /w l l /w r /w l r /y l /rb /y l /ys b l /g ...

  • Page 455: Fuel Pump System

    Fuel pump system 7-64 3. Main switch 4. Main fuse 6. Battery 7. Fuel injection system fuse 11.Relay unit 13.Fuel pump relay 15.Diode 2 (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 17.Fuel pump 27.Ecu (electronic control unit) 68.Engine stop switch 77.Ignition fuse 81.Ecu fuse (for xv19s(c)/ xv19...

  • Page 456: Fuel Pump System

    Fuel pump system 7-65 eas27570 troubleshooting if the fuel pump fails to operate. Note: • before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rider seat bracket assembly 4. Left side cover 5. Headlight assembly ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng → ok ↓ ng ...

  • Page 457: Fuel Pump System

    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

    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: Electrical Components

    Electrical components 7-68 1. Cylinder-#2 right ignition coil (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 2. Cylinder-#2 left ignition coil (for xv19s(c)/ xv19m(c)/ xv19cts(c)/ xv19ctm(c)) 3. Fuel sender 4. Engine temperature sensor 5. Cylinder-#1 left ignition coil (for xv19s(c)/ xv19m(c)/ xv1...

  • Page 460: Electrical Components

    Electrical components 7-69 16 18 2 11 13 9 8 10 12 14 15 17 1 3 4 5 6 7.

  • Page 461: Electrical Components

    Electrical components 7-70 1. Air temperature sensor 2. Main switch 3. Cylinder-#2 intake air pressure sensor 4. Throttle position sensor 5. Cylinder-#1 intake 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)/ x...

  • Page 462: Electrical Components

    Electrical components 7-71 eas27980 checking the switches b b b 11 13 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/y g/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 b r/w b/r g/...

  • Page 463: Electrical Components

    Electrical components 7-72 1. Main switch 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 12. Select switch 13. Turn signal switch.

  • Page 464: Electrical Components

    Electrical components 7-73 check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Caution: eca14370 never insert the tester probes into the coupler terminal slots “a”. Always insert the probe...

  • Page 465: Electrical Components

    Electrical components 7-74 eas27990 checking the bulbs and bulb sockets note: do not check any of the lights that use leds. Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → repair or replace the bulb, bulb socket or ...

  • Page 466: Electrical Components

    Electrical components 7-75 checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) no continuity → replace. Note: check each bulb socket for continuity in the same manner as described in ...

  • Page 467: Electrical Components

    Electrical components 7-76 for xv19cs(c)/ xv19c(c) warning ewa13310 never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfu...

  • Page 468: Electrical Components

    Electrical components 7-77 3. Remove: • coupler tray “1” 4. Disconnect: • battery leads (from the battery terminals) caution: eca13640 first, disconnect the negative battery lead “1”, and then positive battery lead “2”. 5. Remove: • battery 6. Check: • battery charge ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ...

  • Page 469: Electrical Components

    Electrical components 7-78 warning ewa13300 do not quick charge a battery. Caution: eca13670 • never remove the mf battery sealing caps. • do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat- tery overheating and battery plate dam...

  • Page 470: Electrical Components

    Electrical components 7-79 f. If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current. G. Measure the battery open-circuit voltage after leavin...

  • Page 471: Electrical Components

    Electrical components 7-80 starter relay relay unit (starting circuit cut-off relay) relay unit (fuel pump relay) headlight relay et1d71011 checking the turn signal relay 1. Check: • turn signal relay input voltage out of specification → the wiring circuit from the main switch to the turn signal rel...

  • Page 472: Electrical Components

    Electrical components 7-81 b. Turn the main switch to “on”. C. Measure the turn signal relay input voltage. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • turn signal relay output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the ...

  • Page 473: Electrical Components

    Electrical components 7-82 ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the relay unit from the wire har- ness. B. Connect the pocket tester ( Ω × 1) to the relay unit terminals as shown. C. Check the relay unit (diode) for continuity. D. Check the relay unit (diode) for no contin...

  • Page 474: Electrical Components

    Electrical components 7-83 note: the pocket tester and the analog pocket tester readings are shown in the following table. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Disconnect the diode 2 from the wire har- ness. B. Connect the pocket tester ( Ω × 1) to the diode 2 terminals as shown. C. ...

  • Page 475: Electrical Components

    Electrical components 7-84 c. Measure the spark plug cap resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28100 checking the ignition coils the following procedure applies to all of the igni- tion coils. 1. Check: • primary coil resistance out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ...

  • Page 476: Electrical Components

    Electrical components 7-85 b. Measure the crankshaft position sensor re- sistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28130 checking the lean angle sensor 1. Remove: • lean angle sensor 2. Check: • lean angle sensor output voltage out of specification → replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼...

  • Page 477: Electrical Components

    Electrical components 7-86 2. Check: • stator coil resistance out of specification → replace the stator coil. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the pocket tester ( Ω × 1) to the stator coil coupler as shown. B. Measure the stator coil resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲...

  • Page 478: Electrical Components

    Electrical components 7-87 c. Measure the horn resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • horn sound faulty sound → adjust or replace. ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect a battery (12 v) to the horn. B. Turn the adjusting screw in direction “a...

  • Page 479: Electrical Components

    Electrical components 7-88 b. Immerse the engine temperature sensor “1” in a container filled with water “2”. Note: make sure that the engine temperature sensor terminals do not get wet. C. Place a thermometer “3” in the water. D. Slowly heat the water, then let it cool down to the specified tempera...

  • Page 480: Electrical Components

    Electrical components 7-89 b. Measure the fuel sender resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ et1d71044 checking the fuel level warning light this model is equipped with a self-diagnosis de- vice for the fuel level detection circuit. 1. Check: • fuel level warning light “1” (tu...

  • Page 481: Electrical Components

    Electrical components 7-90 b. Measure the throttle position sensor maxi- mum resistance. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 3. Install: • throttle position sensor note: when installing the throttle position sensor, ad- just its angle properly. Refer to “adjusting the throttle position...

  • Page 482: Electrical Components

    Electrical components 7-91 caution: eca14390 to prevent damaging the exup servo motor, perform this test within a few seconds of connecting the battery. ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ eas28410 checking the intake air pressure sensor the following procedure applies to both of the i...

  • Page 483: Troubleshooting

    8 troubleshooting troubleshooting..................................................................................... 8-1 general information ....................................................................... 8-1 starting failures...................................................................

  • Page 484: Troubleshooting

    Troubleshooting 8-1 eas28450 troubleshooting eas28460 general information note: the following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic trouble- shooting. Refer to the relative procedure in this manual for checks, ...

  • Page 485: Troubleshooting

    Troubleshooting 8-2 • improper throttle cable free play • flooded throttle body electrical system 1. Battery • discharged battery • faulty battery 2. Spark plug(s) • incorrect spark plug gap • incorrect spark plug heat range • fouled spark plug • worn or damaged electrode • worn or damaged insulator...

  • Page 486: Troubleshooting

    Troubleshooting 8-3 • deteriorated oil eas28590 overheating engine 1. Cylinder head(s) and piston(s) • heavy carbon buildup 2. Engine oil • incorrect oil level • incorrect oil viscosity • inferior oil quality fuel system 1. Throttle body(-ies) • faulty throttle body(-ies) • damaged or loose throttle...

  • Page 487: Troubleshooting

    Troubleshooting 8-4 eas28710 faulty lighting or signaling system headlight does not come on • wrong headlight bulb • too many electrical accessories • hard charging • incorrect connection • improperly grounded circuit • poor contacts (main switch) • burnt-out headlight bulb headlight bulb burnt out ...

  • Page 488

    Eas28740 wiring diagram xv19sx(c)/xv19mx(c)/xv19ct sx(c)/xv19ctmx(c) 2008 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Main fuse 5. Backup fuse (odometer and clock) 6. Battery 7. Fuel injection system fuse 8. Starter relay 9. Starter motor 10. Diode 1 11. Relay unit 12. Starting circuit cu...

  • Page 489

    Eas1d77006 wiring diagram xv19csx(c)/xv19cx(c) 2008 1. Ac magneto 2. Rectifier/regulator 3. Main switch 4. Main fuse 5. Battery 6. Fuel injection system fuse 7. Starter relay 8. Starter motor 9. Relay unit 10. Starting circuit cut-off relay 11. Fuel pump relay 12. Neutral switch 13. Sidestand switch...

  • Page 492

    Yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.

  • Page 493

    Xv19sx(c)/xv19mx(c)/xv19ctsx(c)/xv19ctmx(c) 2008 wiring diagram (gray) (blue) (blue) (black) (black) (black) (black) (black) (gray) (gray) (gray) (gray) (gray) (blue) (blue) (gray) (black) (black) (black) (black) (black) (black) (black) (gray) (dark gray) (black) (black) (black) (black) (black) (gra...

  • Page 494

    Xv19csx(c)/xv19cx(c) 2008 wiring diagram (gray) on off (blue) (blue) c c (black) (black) b (black) (black) a (black) (black) (gray) (gray) (black) (black) (black) (black) (black) (black) (black) (black) b b a (gray) (gray) (yellow) (yellow) (black) (black) wire harness wire harness sub-wire-harness2...