00 Yamaha Raider Service Manual

2008
SERVICE MANUAL
XV19SX(C)
XV19MX(C)
XV19CTSX(C)
XV19CTMX(C)
XV19CSX(C)
XV19CX(C)
LIT-11616-21-26 1D7-28197-12
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 prohibited.
Printed in U.S.A.
P/N LIT-11616-21-26
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 Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death

WARNING to the vehicle operator, a bystander or a person checking or repairing the ve-
hicle.
A CAUTION indicates special precautions that must be taken to avoid dam-

CAUTION: age to the vehicle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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 divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
EAS20100
1. Serviceable with engine mounted
SYMBOLS 2. Filling fluid
The following symbols are used in this manual 3. Lubricant
for easier understanding. 4. Special tool
NOTE: 5. Tightening torque
The following symbols are not relevant to every 6. Wear limit, clearance
vehicle. 7. Engine speed
8. Electrical data
9. Engine oil
1 2 3 10. Gear oil
11. Molybdenum-disulfide oil
12. Brake fluid
13. Wheel-bearing grease
4 5 6 14. Lithium-soap-based grease
15. Molybdenum-disulfide grease
16. Silicone grease
17. Apply locking agent (LOCTITE®).
T.
R.
18. Replace the part with a new one.

7 8
9 10
E G
11 12
M BF
13 14
B LS
15 16
M S
17 18
LT New
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
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
INSTRUMENT FUNCTIONS (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C)) ........................................................................................... 1-4
INSTRUMENT FUNCTIONS (for XV19CS(C)/ XV19C(C)) .......................1-7
IMPORTANT INFORMATION ....................................................................... 1-11

PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-11
REPLACEMENT PARTS.........................................................................1-11
GASKETS, OIL SEALS AND O-RINGS .................................................. 1-11
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-11
BEARINGS AND OIL SEALS .................................................................. 1-12
CIRCLIPS ................................................................................................1-12
CHECKING THE CONNECTIONS ................................................................1-13
SPECIAL TOOLS .......................................................................................... 1-14

IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame under
the rider seat. This information will be needed to
order spare parts.
1-1
FEATURES
EAS20170
FEATURES
ET1D71017
OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1 2 3 4 5 6 7 8 9 10 11 12 13 14
23 22 18 21 20 19 18 17 16 15
1. Air temperature sensor 12. ECU (electronic control unit)
2. ISC (idle speed control) unit 13. Relay unit (fuel pump relay)
3. Cylinder-#2 intake air pressure sensor 14. EXUP servo motor
4. Engine temperature sensor 15. Speed sensor
5. Cylinder-#2 left and right ignition coils (for 16. O2 sensor
XV19CS(C)/ XV19C(C)) 17. Lean angle sensor
6. Cylinder-#1 right ignition coil (for XV19S(C)/ 18. Spark plug
XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
19. Injector #1
7. Throttle position sensor
20. Crankshaft position sensor
8. Cylinder-#1 left and right ignition coils (for
XV19CS(C)/ XV19C(C)) 21. Injector #2
9. Cylinder-#1 left ignition coil (for XV19S(C)/ 22. Cylinder-#2 right ignition coil (for XV19S(C)/
XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
10. Cylinder-#1 intake air pressure sensor 23. Cylinder-#2 left ignition coil (for XV19S(C)/
11. Fuel pump
1-2
FEATURES
ET1D71018
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 55.7 psi). Accordingly,
when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing
the fuel to be injected into the intake manifold only during the time the passage remains open. There-
fore, the longer the length of time the fuel injector is energized (injection duration), the greater the vol-
ume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature sensor,
engine temperature sensor, speed sensor and O2 sensor enable the ECU to determine the injection
duration. The injection timing is determined through the signals from the crankshaft position sensor. As
a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with
the driving conditions.
Illustration is for reference only.
6
7
1 8
2 C
A 5
3
#2 #1
4 9
15 10
B
14
13 11
12
1. Pressure regulator 13. Intake air pressure sensor

2. Fuel pump 14. Throttle body
3. Fuel injector 15. Air filter case
4. Ignition coil
A. Fuel system
5. ECU (electronic control unit)
B. Air system
6. Air temperature sensor
C. Control system
7. ISC (idle speed control) unit
9. O2 sensor
10. Catalytic converter
11. Engine temperature sensor
1-3
FEATURES
ET1D71036
INSTRUMENT FUNCTIONS (for XV19S(C)/

Multi-function meter unit

EW1D71008
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit.
4 2
3
1. “SELECT” switch
1. Speedometer
2. “RESET” switch
2. Fuel gauge
3. Odometer/tripmeter/fuel reserve
tripmeter/clock Speedometer
4. Tachometer
1
The multi-function meter unit is equipped with
the following:
• a speedometer (which shows the riding speed)
• a tachometer (which shows the engine speed)
• a fuel gauge
• an odometer (which shows the total distance
traveled)
• two tripmeters (which show the distance trav-
eled since they were last set to zero)
1. Speedometer
• a fuel reserve tripmeter (which shows the dis-
tance traveled on the fuel reserve) The speedometer shows the riding speed.
• a clock When the key is turned to “ON”, the speedome-
• a self-diagnosis device ter needle will sweep once across the speed
• a brightness control mode range and then return to zero in order to test the
NOTE: electrical circuit.
• Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” switches, except for
setting the brightness control mode.
• To switch the odometer, the tripmeters and the
fuel reserve tripmeter displays between kilo-
meters and miles, press the “SELECT” switch
for at least two seconds. (for USA and Califor-
nia only)
1-4
FEATURES
Tachometer • The fuel gauge does not indicate the correct

fuel level for the first 5 km/h (3 mi/h) after refu-
eling.
Odometer, tripmeter, and clock modes

1
1. Tachometer
2. Tachometer red zone
The electric tachometer allows the rider to mon- 1
itor the engine speed and keep it within the ideal
power range. 1. Odometer/tripmeter/fuel reserve
When the key is turned to “ON”, the tachometer tripmeter/clock
needle will sweep once across the r/min range Push the “SELECT” switch to switch the display
and then return to zero r/min in order to test the between the odometer mode “ODO”, the tripme-
electrical circuit. ter modes “TRIP 1” and “TRIP 2” and the clock
EC1D71017
mode in the following order:
CAUTION:
ODO → TRIP 1 → TRIP 2 → Clock → ODO
Do not operate the engine in the tachometer If the fuel level warning light comes on, the
red zone. odometer display will automatically change to
Red zone: 5000 r/min and above the fuel reserve tripmeter mode “F-TRIP” and
start counting the distance traveled from that
Fuel gauge point. In that case, push the “SELECT” switch to
switch the display between the various tripme-
ter, odometer, and clock modes in the following
order:
F-TRIP → TRIP 1 → TRIP 2 → Clock → ODO →
F-TRIP
To reset a tripmeter, select it by pushing the “SE-
1
LECT” switch, and then push the “RESET”
switch for at least one second. If you do not reset
the fuel reserve tripmeter manually, it will reset
itself automatically, and the display will return to
1. Fuel gauge the prior mode after refueling and traveling 5 km
(3 mi).
The fuel gauge indicates the amount of fuel in
the fuel tank. The needle moves towards “E” Clock mode
(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.
When the key is turned to “ON”, the fuel gauge
needle will sweep once across the fuel level
range and then return to the current amount in
order to test the electrical circuit.
NOTE:
• Do not allow the fuel tank to empty itself com-
pletely. 1. Clock
1-5
FEATURES
To set the clock: Select the brightness control mode as follows.

1. Push the “SELECT” switch to change the dis- 1. Turn the key to “OFF”.
play to the clock mode. 2. Push and hold the “SELECT” switch.
2. Push the “SELECT” and “RESET” switches 3. Turn the key to “ON”, and then release the
together for at least two seconds. “SELECT” switch after five seconds.
3. When the hour digits start flashing, push the Item number “1” is displayed.
“RESET” switch to set the hours.
4. Push the “SELECT” switch, and the minute
digits will start flashing.
5. Push the “RESET” switch to set the minutes. 1
6. Push the “SELECT” switch and then release
it to start the clock.
Self-diagnosis device 2
This model is equipped with a self-diagnosis de- 3
vice for various electrical circuits.
If any of those circuits are defective, the engine 1. Multi-function meter unit panel
trouble warning light will come on, and then the 2. Item number
odometer/tripmeter/clock display will indicate a 3. Brightness level
two-digit error code (e.g., 12, 13, 14).
If the odometer/tripmeter/clock display indicates 4. Adjust the multi-function meter unit panel
any error codes, note the code number, and brightness level by pushing the “RESET”
then check the vehicle. Refer to “FUEL INJEC- switch.
TION SYSTEM” on page 7-27. 5. Push the “SELECT” switch to select the LCD.
EC1D71018 Item number “2” is displayed.
CAUTION: Adjust the LCD brightness level by pushing
If the display indicates an error code, the ve- the “RESET” switch.
hicle should be checked as soon as possible
in order to avoid engine damage.
Brightness control mode
1 1 2
3 3
4
5 1. LCD
2 2. Item number
3. Brightness level
6. Push the “SELECT” switch to select the
1. Multi-function meter unit panel speedometer, tachometer, and the fuel
2. LCD gauge needles.
3. Speedometer needle Item number “3” is displayed.
4. Tachometer needle Adjust the brightness level of the speedome-
5. Fuel gauge needle ter, tachometer, and the fuel gauge needles
by pushing the “RESET” switch.
The brightness can be adjusted for the following:
• the multi-function meter unit panel (item num-
ber “1”)
• the LCD (item number “2”)
• the speedometer, tachometer, and the fuel
gauge needles (item number “3”)
1-6
FEATURES
• a fuel reserve tripmeter (which shows the dis-

tance traveled on the fuel reserve)
1 • a clock
• a self-diagnosis device
2 • a brightness control mode
3 NOTE:
4 Be sure to turn the key to “ON” before using the
“SELECT” and reset switches, except for setting
5
the brightness control mode.
1. Speedometer needle
2. Tachometer needle
3. Fuel gauge needle
4. Item number
5. Brightness level
7. Push the “SELECT” switch.
The odometer/tripmeter/clock display will re-
turn to the prior mode.
EAS1D77010
INSTRUMENT FUNCTIONS (for XV19CS(C)/ 1. “SELECT” switch

XV19C(C))
Multi-function meter unit

60 100 70 12020 80 90
5080 140
40
100
160
40
60
110
30 180
40
120
20 200
20 130
10 220
0
0
km/h 140
MPH
1. Reset switch
1. Speedometer Speedometer
tripmeter/clock
3. Fuel gauge
EWA1D77001
WARNING
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 speedometer (which shows the riding speed) 1. Speedometer
• a fuel gauge
• an odometer (which shows the total distance When the key is turned to “ON”, the speedome-
traveled) ter needle will sweep once across the speed
• two tripmeters (which show the distance trav- range and then return to zero in order to test the
eled since they were last set to zero) electrical circuit.
1-7
FEATURES
Fuel gauge b. Estimation range

c. Main fuel tank estimation range
d. Sub-fuel tank estimation range
e. Fuel level warning light activation point
f. Main fuel tank
g. Sub-fuel tank
These models are equipped with two fuel tanks:
the main fuel tank and the sub-fuel tank. Since
the fuel sender, which is used to detect the fuel
level, is installed in the main fuel tank, it is not
able to detect the fuel level throughout the entire
1. Fuel gauge range, which includes the sub-fuel tank. (The
fuel sender detection range is from the full level
The fuel gauge indicates the amount of fuel in [approximately 16 L (4.23 US gal) (3.52
the fuel tank. The needle moves towards “E” Imp.gal)] to the half-full level [approximately 8 L
(Empty) as the fuel level decreases. When the (2.11 US gal) (1.72 Imp.gal)].)
needle reaches “E”, approximately 3.0 L (0.79 For the fuel level range that the fuel sender is not
US gal) (0.66 Imp.gal) remain in the fuel tank. If able to detect, the fuel level is calculated using
this occurs, refuel as soon as possible. the distance traveled and preset fuel consump-
When the key is turned to “ON”, the fuel gauge tion values according to vehicle speed. (The es-
needle will sweep once across the fuel level timation range is from 0 L to the half-full level
range and then return to the current amount in [approximately 8 L (2.11 US gal) (1.72
order to test the electrical circuit. Imp.gal)].)
NOTE: The fuel gauge operates according to the fuel
• Do not allow the fuel tank to empty itself com- sender in the detection range “a” and according
pletely. to the estimation in the range “b”.
• The fuel gauge does not indicate the correct When the fuel level reaches the fuel level warn-
fuel level for the first 5 km/h (3 mi/h) after refu- ing light activation point “e”, the warning light is
eling. activated by the fuel pump thermistor in the sub-
Operation of the fuel gauge and fuel level warn- fuel tank.
ing light Operation of the fuel gauge and fuel level warn-
ing light after refueling
If the fuel level remains in the estimation range
“b” after refueling, the fuel gauge will not oper-
ate. However, if the fuel level reaches the fuel
sender detection range “a”, the fuel gauge will
a
operate and the fuel level will be displayed.
The fuel level warning light will go off when the
c fuel level is above the activation point “e”, even
d if the fuel level remains in the estimation range.
e
b
f
a
b
e
a. Fuel sender detection range
1-8
FEATURES
Odometer, tripmeters, fuel reserve tripmeter 1. Push the “SELECT” and reset switches to-
and clock gether for at least three seconds.
2. When the hour digits start flashing, push the
reset switch to set the hours.
3. Push the “SELECT” switch, and the minute
digits will start flashing.
4. Push the reset switch to set the minutes.
5. Push the “SELECT” switch and then release
it to start the clock.
Self-diagnosis devices
This model is equipped with a self-diagnosis de-
vice for various electrical circuits.
tripmeter/clock If any of those circuits are defective, the engine
trouble warning light will come on, and then the
Push the “SELECT” switch to change the display odometer/tripmeter/clock display will indicate a
between the odometer mode “ODO”, the tripme- two-digit error code.
ter modes “TRIP A” and “TRIP B” in the following If the odometer/tripmeter/clock display indicates
order: any error codes, note the code number, and
ODO → TRIP A → TRIP B → ODO then have a Yamaha dealer check the vehicle.
If the fuel level warning light comes on, the ECA1D77001
odometer display will automatically change to CAUTION:

the fuel reserve tripmeter mode “F-TRIP” and If the display indicates an error code, the ve-
start counting the distance traveled from that hicle should be checked as soon as possible
point. In that case, push the “SELECT” switch to in order to avoid engine damage.
change the display between the various tripme-
ter and odometer modes in the following order: Brightness control mode
F-TRIP → TRIP A → TRIP B → ODO → F-TRIP
To reset a tripmeter, select it by pushing the “SE-
LECT” switch, and then push the reset switch for
at least one second. If you do not reset the fuel
reserve tripmeter manually, it will reset itself au-
tomatically, and the display will return to the prior
mode after refueling and traveling 5 km (3 mi).
To set the clock
1. Multi-function meter unit panel

This function allows you to adjust the brightness
of the multi-function meter unit panel to suit the
outside lighting conditions.
1. Clock
1-9
FEATURES
To set the brightness

1. Turn the key to “OFF”.
2. Push and hold the “SELECT” switch.
3. Turn the key to “ON”, and then release the
“SELECT” switch after five seconds.
1. Multi-function meter unit panel

2. Brightness level
4. Adjust the multi-function meter unit panel
brightness level by pushing the reset switch.
5. Push the “SELECT” switch.
The odometer/tripmeter/clock display will re-
turn to the prior mode.
1-10
IMPORTANT INFORMATION
EAS20180
EAS20190
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-14.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER

PINS
4. During disassembly, clean all of the parts and After removal, replace all lock washers/plates
place them in trays in the order of disassem- “1” and cotter pins. After the bolt or nut has been
bly. This will speed up assembly and allow for tightened to specification, bend the lock tabs
the correct installation of all parts. along a flat of the bolt or nut.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-11
EAS20230
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropri-
ate.
ECA13300
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-12
CHECKING THE CONNECTIONS
EAS20250
CHECKING THE CONNECTIONS Pocket tester

Check the leads, couplers, and connectors for 90890-03112
stains, rust, moisture, etc. Analog pocket tester
1. Disconnect: YU-03112-C
• Lead
• Coupler NOTE:
• Connector • If there is no continuity, clean the terminals.
2. Check: • When checking the wire harness, perform
• Lead steps (1) to (3).
• Coupler • As a quick remedy, use a contact revitalizer
• Connector available at most part stores.
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
• Lead
• Coupler
• Connector
NOTE:
Make sure all connections are tight.
5. Check:
• Continuity
(with the pocket tester)
1-13
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-13, 5-84,
90890-03112 7-73, 7-74,
Analog pocket tester 7-75, 7-79,
YU-03112-C 7-80, 7-81,
7-82, 7-83,
7-84, 7-85,
7-86, 7-87,
7-88, 7-89,
7-91
Thickness gauge 3-6, 5-65
90890-03180
Feeler gauge set
YU-26900-9
Tappet adjusting tool (4 mm) 3-6, 3-7

90890-04133
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Vacuum gauge 3-7
90890-03094
Carburetor synchronizer
YU-44456
YU-44456
1-14
SPECIAL TOOLS
Reference
pages
Timing light 3-10
90890-03141
Inductive clamp timing light
YU-03141
Oil filter wrench 3-12

90890-01426
YU-38411
Belt tension gauge 3-26

90890-03170
Rear drive belt tension gauge
YM-03170
Steering nut wrench 3-27, 4-81

90890-01403
Spanner wrench
YU-33975
Damper rod holder 4-71, 4-73

90890-01460
T-handle 4-71, 4-73

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver 4-73, 4-74

90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Pivot shaft wrench 5-15

90890-01485
Frame mount insert wrench
YM-01485
Valve spring compressor 5-42, 5-47

90890-04019
YM-04019
1-15
SPECIAL TOOLS
Reference
pages
Valve guide remover (ø6) 5-43
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6) 5-43

90890-04065
Valve guide installer (6.0 mm)
YM-04065-A
Valve guide reamer (ø6) 5-43

90890-04066
Valve guide reamer (6.0 mm)
YM-04066
Piston pin puller set 5-49

90890-01304
Piston pin puller
YU-01304
YU-01304
Universal clutch holder 5-64, 5-69

90890-04086
YM-91042
Sheave holder 5-64, 5-68,

90890-01701 5-79, 5-80
Primary clutch holder
YS-01880-A
1-16
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-70, 5-80,
90890-85505 5-98
(Three Bond No.1215®)
Rotor puller 5-79

90890-01080
Stator rotor puller
YM-01080-A
Vacuum/pressure pump gauge set 6-16

90890-06756
Mityvac brake bleeding tool
YS-42423
Pressure gauge 6-16

90890-03153
YU-03153
Fuel pressure adapter 6-16

90890-03176
YM-03176
Digital circuit tester 6-16

90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Ignition checker 7-83

90890-06754
Opama pet-4000 spark checker
YM-34487
1-17
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-3
CHASSIS SPECIFICATIONS ........................................................................2-11
ELECTRICAL SPECIFICATIONS .................................................................2-16
TIGHTENING TORQUES .............................................................................. 2-20

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-20
ENGINE TIGHTENING TORQUES......................................................... 2-21
CHASSIS TIGHTENING TORQUES.......................................................2-26
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-33

ENGINE................................................................................................... 2-33
CHASSIS.................................................................................................2-35
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-37

ENGINE OIL LUBRICATION CHART .....................................................2-37
LUBRICATION DIAGRAMS .................................................................... 2-39
CABLE ROUTING
(for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) ............................ 2-51
CABLE ROUTING (for XV19CS(C)/ XV19C(C))...........................................2-67

GENERAL SPECIFICATIONS
EAS20280
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 (California)
XV19CTMX 4P19 (CDN)
XV19CSX 29P1/5C71 (USA)
XV19CSXC 29P2/5C72 (California)
XV19CSX 29P3/5C73 (CDN)
XV19CX 29S1/30B1 (USA)
XV19CXC 29S2/30B2 (California)
XV19CX 29S3/30B3 (CDN)
Dimensions
Overall length XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
2580 mm (101.6 in)
XV19CS(C)/ XV19C(C):
2572 mm (101.3 in)
Overall width XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
1100 mm (43.3 in)
925 mm (36.4 in)
Overall height XV19S(C)/ XV19M(C):
1100 mm (43.3 in)
XV19CTS(C)/ XV19CTM(C):
1515 mm (59.6 in)
1165 mm (45.9 in)
Seat height XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
735 mm (28.9 in)
695 mm (27.4 in)
Wheelbase XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
1715 mm (67.5 in)
1799 mm (70.8 in)
2-1
Ground clearance XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C):
155 mm (6.10 in)
146 mm (5.75 in)
Minimum turning radius XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
3480 mm (137.0 in)
3500 mm (137.8 in)
Weight
With oil and fuel XV19S(C)/ XV19M(C):
340.0 kg (750 lb)
364.0 kg (802 lb)
331.0 kg (730 lb)
Maximum load XV19S(C)/ XV19M(C):
210 kg (463 lb)
186 kg (410 lb)
204 kg (450 lb)
2-2
ENGINE SPECIFICATIONS
EAS20290
Engine
Engine type Air cooled 4-stroke, OHV
Displacement 1854.0 cm³
Cylinder arrangement V-type 2-cylinder
Bore × stroke 100.0 × 118.0 mm (3.94 × 4.65 in)
Compression ratio 9.48 :1
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
17.0 L (4.49 US gal) (3.74 Imp.gal)
15.9 L (4.20 US gal) (3.50 Imp.gal)
Fuel reserve amount XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
3.0 L (0.79 US gal) (0.66 Imp.gal)
3.2 L (0.85 US gal) (0.70 Imp.gal)
Engine oil
Lubrication system Dry sump
Type YAMALUBE 4 (20W40) or SAE20W40
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 5.20 L (5.50 US qt) (4.58 Imp.qt)
Engine 3.2 L (3.38 US qt) (2.82 Imp.qt)
Oil tank 2.0 L (2.11 US qt) (1.76 Imp.qt)
Without oil filter cartridge replacement 4.10 L (4.33 US qt) (3.61 Imp.qt)
With oil filter cartridge replacement 4.90 L (5.18 US qt) (4.31 Imp.qt)
Oil pressure (hot) 60.0 kPa/900 r/min (8.7 psi/900 r/min) (0.60
kgf/cm²/900 r/min)
Transfer gear oil

Type SAE80 API GL-4 Hypoid gear oil
Quantity (disassembled) 0.60 L (0.63 US qt) (0.53 Imp.qt)
Quantity 0.55 L (0.58 US qt) (0.48 Imp.qt)
Oil filter
Oil filter type Cartridge (paper)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09–0.19 mm (0.0035–0.0075 in)
Limit 0.26 mm (0.0102 in)
2-3
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.13 mm (0.0024–0.0051 in)
Limit 0.20 mm (0.0079 in)
Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20
kgf/cm²)
Relief valve operating pressure 600.0 kPa (87.0 psi) (6.00 kgf/cm²)
Transfer gear oil pump

Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.10–0.15 mm (0.0039–0.0059 in)
Limit 0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.04–0.09 mm (0.0016–0.0035 in)
Limit 0.160 mm (0.0063 in)
Spark plug (s)

Manufacturer/model NGK/DPR8EA-9
Manufacturer/model DENSO/X24EPR-U9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Volume 80.90–84.90 cm³ (4.94–5.18 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Gear drive
Crankcase hole inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
Camshaft journal diameter (crankcase side) 24.957–24.980 mm (0.9826–0.9835 in)
Camshaft to crankcase clearance 0.020–0.064 mm (0.0008–0.0025 in)
Camshaft cover hole inside diameter 28.000–28.021 mm (1.1024–1.1032 in)
Camshaft journal diameter (camshaft cover side) 27.957–27.980 mm (1.1007–1.1016 in)
Camshaft to camshaft cover clearance 0.020–0.064 mm (0.0008–0.0025 in)
Camshaft lobe dimensions
Intake A 42.532–42.632 mm (1.6745–1.6784 in)
Limit 42.432 mm (1.6705 in)
Intake B 35.950–36.050 mm (1.4154–1.4193 in)
Limit 35.850 mm (1.4114 in)
Exhaust A 42.530–42.630 mm (1.6744–1.6783 in) (cylinder
#1)
42.531–42.631 mm (1.6744–1.6784 in) (cylinder
#2)
Limit 42.430 mm (1.6705 in) (cylinder #1)
42.431 mm (1.6705 in) (cylinder #2)
Exhaust B 35.950–36.050 mm (1.4154–1.4193 in)
2-4
Limit 35.850 mm (1.4114 in)
Rocker arm/rocker arm shaft

Rocker arm inside diameter 18.000–18.018 mm (0.7087–0.7094 in)
Limit 18.036 mm (0.7101 in)
Rocker arm shaft outside diameter 17.976–17.991 mm (0.7077–0.7083 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in)
Limit 0.080 mm (0.0032 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.00–0.04 mm (0.0000–0.0016 in)
Exhaust 0.00–0.04 mm (0.0000–0.0016 in)
Valve dimensions
Valve head diameter A (intake) 35.90–36.10 mm (1.4134–1.4213 in)
Valve head diameter A (exhaust) 30.90–31.10 mm (1.2165–1.2244 in)
A
Valve seat width C (intake) 1.10–1.30 mm (0.0433–0.0512 in)
Limit 2.0 mm (0.08 in)
Valve seat width C (exhaust) 1.10–1.30 mm (0.0433–0.0512 in)
Valve margin thickness D (intake) 1.15–1.45 mm (0.0453–0.0571 in)

Valve margin thickness D (exhaust) 1.15–1.45 mm (0.0453–0.0571 in)
Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in)

Limit 5.945 mm (0.2341 in)
Valve stem diameter (exhaust) 5.960–5.975 mm (0.2346–0.2352 in)
Limit 5.920 mm (0.2331 in)
Valve guide inside diameter (intake) 6.000–6.012 mm (0.2362–0.2367 in)
Limit 6.050 mm (0.2382 in)
Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in)
2-5
Limit 6.050 mm (0.2382 in)

Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Valve spring
Free length (intake) 46.71 mm (1.84 in)
Limit 44.71 mm (1.76 in)
Free length (exhaust) 46.71 mm (1.84 in)
Limit 44.71 mm (1.76 in)
Installed length (intake) 32.66 mm (1.29 in)
Installed length (exhaust) 32.66 mm (1.29 in)
Spring rate K1 (intake) 16.58 N/mm (94.67 lb/in) (1.69 kgf/mm)
Spring rate K2 (intake) 21.98 N/mm (125.51 lb/in) (2.24 kgf/mm)
Spring rate K1 (exhaust) 16.58 N/mm (94.67 lb/in) (1.69 kgf/mm)
Spring rate K2 (exhaust) 21.98 N/mm (125.51 lb/in) (2.24 kgf/mm)
Installed compression spring force (intake) 217.00–249.00 N (48.78–55.98 lb) (22.13–
25.39 kgf)
Installed compression spring force (exhaust) 217.00–249.00 N (48.78–55.98 lb) (22.13–
25.39 kgf)
Spring tilt (intake) 2.5 °/2.0 mm
Spring tilt (exhaust) 2.5 °/2.0 mm
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Valve lifter
Valve lifter outside diameter (intake) 22.962–22.974 mm (0.9040–0.9045 in)
Valve lifter outside diameter (exhaust) 22.962–22.974 mm (0.9040–0.9045 in)
Valve lifter hole inside diameter (intake) 23.000–23.021 mm (0.9055–0.9063 in)
Valve lifter hole inside diameter (exhaust) 23.000–23.021 mm (0.9055–0.9063 in)
Valve-lifter-to-valve-lifter-hole clearance 0.026–0.059 mm (0.0010–0.0023 in)
Valve push rod

Valve push rod 1 length 286.5 mm (11.280 in)
Valve push rod 2 length 288.5 mm (11.358 in)
Valve push rod runout 0.3 mm (0.012 in)
2-6
Cylinder
Bore 100.000–100.010 mm (3.9370–3.9374 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.025–0.050 mm (0.0010–0.0020 in)
Limit 0.15 mm (0.0059 in)
Diameter D 99.960–99.975 mm (3.9354–3.9360 in)
Height H 10.0 mm (0.39 in)
H
D
Offset 0.50 mm (0.0197 in)

Piston pin bore inside diameter 23.004–23.015 mm (0.9057–0.9061 in)
Limit 23.045 mm (0.9073 in)
Piston pin outside diameter 22.991–23.000 mm (0.9052–0.9055 in)
Limit 22.971 mm (0.9044 in)
Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.00016–0.00094 in)
Limit 0.074 mm (0.00291 in)
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in)
B
T
End gap (installed) 0.20–0.35 mm (0.0079–0.0138 in)

Limit 0.55 mm (0.0217 in)
Ring side clearance 0.030–0.080 mm (0.0012–0.0032 in)
Limit 0.120 mm (0.0047 in)
2nd ring
Ring type Taper
B
T

Limit 0.95 mm (0.0374 in)
Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in)
Limit 0.120 mm (0.0047 in)
2-7
Oil ring
B
T
Connecting rod
Oil clearance (using plastigauge®) 0.050–0.074 mm (0.0020–0.0029 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow
Crankshaft
Width A 105.80–106.20 mm (4.165–4.181 in)
Runout limit C 0.040 mm (0.0016 in)
Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in)
Big end radial clearance E 0.037–0.074 mm (0.0015–0.0029 in)
Limit 0.09 mm (0.0035 in)
Journal oil clearance (using plastigauge®) 0.030–0.062 mm (0.0012–0.0024 in)

Limit 0.10 mm (0.0039 in)
Clutch
Clutch type Wet, multiple-disc
Clutch release method Hydraulic inner push
Operation Left hand operation
Friction plate 1, 3 thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.110 in)
Plate quantity 10 pcs
Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.82 mm (0.111 in)
Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in)
Warpage limit 0.20 mm (0.0079 in)
Clutch spring free length 6.78 mm (0.27 in)
Minimum length 6.28 mm (0.25 in)
Spring quantity 1 pcs
Clutch housing thrust clearance 0.100–0.110 mm (0.0039–0.0043 in)
Clutch housing radial clearance 0.020–0.066 mm (0.0008–0.0026 in)
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 72/51 (1.412)
2-8
Secondary reduction system Belt drive

Secondary reduction ratio XV19SX(C)/ XV19MX(C)/ XV19CTSX(C)/
XV19CTMX(C):
70/31 (2.258)
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)
5th 24/30 (0.800)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type Guide bar
Shift fork guide bar bending limit 0.025 mm (0.0010 in)
Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in)
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Model/manufacturer 1D7/MITSUBISHI
Maximum consumption amperage 5.5 A
Output pressure 441.0–637.0 kPa (63.9–92.4 psi) (4.41–6.37
kgf/cm²)
Fuel injection
Model/quantity INP-101/2
Manufacturer NIPPON INJECTOR
Throttle body
Type/quantity AC43/2
Manufacturer MIKUNI
ID mark XV19SX/ XV19MX/ XV19CTSX/ XV19CTMX:
1D71 00
XV19SXC/ XV19MXC/ XV19CTSXC/
XV19CTMXC:
1D72 10
XV19CX/ XV19CSX:
5C71 00
XV19CXC/ XV19CSXC:
5C72 10
Throttle valve size #100
2-9
Throttle position sensor

Resistance XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
4.0–6.0 kΩ/blue-black
3.1–5.7 kΩ/blue-black
Output voltage (at idle) 0.63–0.73 V
Fuel injection sensor

Crankshaft position sensor resistance 248–372 Ω
Intake air pressure sensor output voltage 3.75–4.25 V
Engine temperature sensor resistance 0.90–1.10 kΩ at 100 °C (212 °F)
Idling condition
Engine idling speed 850–950 r/min
Intake vacuum 31.3–35.3 kPa (9.2–10.4 inHg) (235–265
mmHg)
Oil temperature 80.0–90.0 °C (176.00–194.00 °F)
Throttle cable free play 4.0–6.0 mm (0.16–0.24 in)
2-10
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Double cradle
Caster angle XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
31.30 °
33.20 °
Trail XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
152.0 mm (5.98 in)
102.0 mm (4.02 in)
Front wheel
Wheel type Cast wheel
Rim size XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
18M/C × MT4.00
21M/C × MT3.50
Rim material Aluminum
Wheel travel 130.0 mm (5.12 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
17M/C × MT5.50
18M/C × MT7.50
Rim material Aluminum
Wheel travel XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
110.0 mm (4.33 in)
90.0 mm (3.54 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
130/70R18M/C 63H
120/70–21M/C 62H
2-11
Manufacturer/model XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C):
DUNLOP/D251F
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
Type Tubeless
Size XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
190/60R17M/C 78H
210/40R18M/C 73H
XV19CTM(C):
DUNLOP/D251
XV19CTM(C):
BRIDGESTONE/G850 RADIAL G
Manufacturer/model XV19CS(C)/ XV19C(C):
Wear limit (rear) 1.0 mm (0.04 in)
Tire air pressure (measured on cold tires)

Loading condition 0–90 kg (0–198 lb)
Front 250 kPa (36 psi) (2.50 kgf/cm²)
Rear 280 kPa (41 psi) (2.80 kgf/cm²)
Loading condition XV19S(C)/ XV19M(C):
90–210 kg (198–463 lb)
90–186 kg (198–410 lb)
XV19CS(C)/ XV19C(C)
90–204 kg (198–450 lb)
High-speed riding
Front brake
Type Dual disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness (inner) 5.5 mm (0.22 in)
Brake pad lining thickness (outer) 5.5 mm (0.22 in)
2-12

Master cylinder inside diameter 14.00 mm (0.55 in)
Caliper cylinder inside diameter 27.00 mm (1.06 in)
Recommended fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Brake pedal position XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
110.0 mm (4.33 in)
93.0 mm (3.66 in)
Rear disc brake
Disc outside diameter × thickness XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
320.0 × 6.0 mm (12.60 × 0.24 in)
310.0 × 6.0 mm (12.20 × 0.24 in)
Brake disc thickness limit 5.5 mm (0.22 in)
Brake disc deflection limit 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 5.8 mm (0.23 in)
Brake pad lining thickness (outer) 5.8 mm (0.23 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Recommended fluid DOT 4
Steering
Steering bearing type Taper roller bearing
Lock to lock angle (left) 35.0 °
Lock to lock angle (right) 35.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm (5.12 in)
Fork spring free length XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
273.9 mm (10.78 in)
407.0 mm (16.02 in)
Limit XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
268.4 mm (10.57 in)
398.9 mm (15.70 in)
Collar length 230.0 mm (9.06 in)
2-13
Installed length XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C):
268.9 mm (10.59 in)
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)
8.34 N/mm (47.0 lb/in) (0.84 kgf/mm)
Spring stroke K1 XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
0.0–30.0 mm (0.00–1.18 in)
130.0 mm (5.12 in)
XV19CTM(C):
12.0 N/mm (68.5 lb/in) (1.22 kgf/mm)
XV19CTM(C):
30.0–130.0 mm (1.18–5.12 in)
Inner tube outer diameter 46.0 mm (1.81 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Yamaha fork oil 10WT
Quantity XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
571.0 cm³ (19.31 US oz) (20.10 Imp.oz)
755.0 cm³ (25.53 US oz) (26.58 Imp.oz)
Level XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
124.0 mm (4.88 in)
117.0 mm (4.61 in)
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
50.0 mm (1.97 in)
40.0 mm (1.57 in)
Spring free length XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
180.0 mm (7.09 in)
187.0 mm (7.36 in)
2-14
Limit XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C):
176.4 mm (6.94 in)
183.3 mm (7.22 in)
Installed length XV19S(C)/ XV19M(C):
171.0 mm (6.73 in)
165.0 mm (6.50 in)
172 mm (6.77 in)
XV19CTM(C):
176.50 N/mm (1007.82 lb/in) (18.00 kgf/mm)
186.20 N/mm (1063.18 lb/in) (18.99 kgf/mm)
XV19CTM(C):
0.0–50.0 mm (0.00–1.97 in)
0.0–40.0 mm (0.00–1.57 in)
Optional spring available No
Enclosed gas/air pressure (STD) 0.98 MPa (139.4 psi) (9.8 kgf/cm²)
Spring preload adjusting positions Installed spring length
Minimum XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
162.0 mm (6.38 in)
163.0 mm (6.42 in)
Standard XV19S(C)/ XV19M(C):
171.0 mm (6.73 in)
165.0 mm (6.50 in)
172.0 mm (6.77 in)
Maximum XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
171.0 mm (6.73 in)
172.0 mm (6.77 in)
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 1.0 mm (0.04 in)
Drive belt
Model/manufacturer UBD-0732/GATES CORPORATION
Drive belt slack (on the sidestand) 7.5–13 mm (0.30–0.51 in)
Drive belt slack (on a suitable stand) 14–21 mm (0.55–0.83 in)
2-15
ELECTRICAL SPECIFICATIONS
EAS20310
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(C)/
XV19CTM(C):
F008T83271/MITSUBISHI
F008T83971/MITSUBISHI
Ignition coil
Model/manufacturer 2JN/YAMAHA
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap

Material Resin
Resistance 10.0 kΩ
AC magneto
Model/manufacturer F4T38971/MITSUBISHI
Standard output 14.0 V 32.0 A 5000 r/min
Stator coil resistance 0.112–0.168 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer FH012AA/SHINDENGEN
No load regulated voltage 14.2–14.8 V
Rectifier capacity 50.0 A
Withstand voltage 40.0 V
Battery
Model GT14B-4
Voltage, capacity 12 V, 12.0 Ah
Manufacturer GS YUASA
Ten hour rate amperage 1.20 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Low beam headlight XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
12 V, 51.0 W × 1
2-16
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 light XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
12 V, 5.0 W
12 V, 3.8 W × 2
Meter lighting LED
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Fuel level warning light LED
Engine trouble warning light LED
Electric starting system

System type Constant mesh
Starter motor
Model/manufacturer 1D7/YAMAHA
Power output 0.90 kW
Armature coil resistance 0.0081–0.0099 Ω
Brush overall length 9.8 mm (0.39 in)
Limit 5.00 mm (0.20 in)
Brush spring force 7.36–11.04 N (26.49–39.74 oz) (750–1126 gf)
Commutator diameter 28.5 mm (1.12 in)
Limit 27.5 mm (1.08 in)
Mica undercut (depth) 1.50 mm (0.06 in)
Starter relay
Model/manufacturer 2768079-A/JIDECO
Amperage 180.0 A
Coil resistance 4.18–4.62 Ω
Horn
Horn type Eddy
Quantity 2 pcs
Model/manufacturer YP-12/NIKKO
Maximum amperage 2.0 A
Coil resistance 0.94–0.98 Ω
Performance 95–115 dB/2m
Turn signal relay

Relay type Semi transistor
Model/manufacturer FB246H/DENSO
Built-in, self-canceling device Yes
2-17
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
5C7/NIPPON SEIKI
Sender unit resistance (full) 9–11 Ω
Sender unit resistance (empty) 213–219 Ω
Starting circuit cut-off relay

Model/manufacturer G8R-30Y-V3/OMRON
Coil resistance 162–198 Ω
Headlight relay
Model/manufacturer ACM33211M05/MATSUSHITA
Fuel pump relay

Model/manufacturer G8R-30Y-V3/OMRON
Coil resistance 162–198 Ω
Thermo unit
Model/manufacturer 5PX/DENSO
Resistance at 100°C 898.4–1098.0 Ω
Fuses
Main fuse 50.0 A
Headlight fuse 20.0 A
Taillight fuse XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
10.0 A
7.5 A
Signaling system fuse 10.0 A
Ignition fuse 25.0 A
Auxiliary DC connector fuse 3.0 A
ECU fuse XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
10.0 A
Fuel injection system fuse 15.0 A
Backup fuse XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C):
10.0 A
7.5 A
Spare fuse 25.0 A
Spare fuse 20.0 A
Spare fuse 15.0 A
Spare fuse 10.0 A
Spare fuse XV19CS(C)/ XV19C(C):
7.5 A
2-18
Spare fuse 3.0 A
2-19
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-20
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Cylinder head nut M12 8 60 Nm (6.0 m·kg, 43 ft·lb) E
Cylinder head stud bolt (exhaust

M8 4 15 Nm (1.5 m·kg, 11 ft·lb)
pipe)
Spark plug M12 4 18 Nm (1.8 m·kg, 13 ft·lb)
Engine temperature sensor — 1 20 Nm (2.0 m·kg, 14 ft·lb)
Rocker arm base bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rocker arm base bolt M8 8 24 Nm (2.4 m·kg, 17 ft·lb)
Cylinder head cover bolt M6 28 10 Nm (1.0 m·kg, 7.2 ft·lb)
See
Connecting rod bolt (1st) M8 4 15 Nm (1.5 m·kg, 11 ft·lb) NOTE.
M
See
Connecting rod bolt (final) M8 4 Specified angle 125–135° NOTE.
M
Right balancer driven gear bolt M10 1 40 Nm (4.0 m·kg, 29 ft·lb) E
Left balancer drive gear bolt M10 1 40 Nm (4.0 m·kg, 29 ft·lb) E
Left balancer driven gear housing

M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
screw
Left balancer weight bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Left balancer idle gear shaft bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Camshaft driven gear bolt M10 1 60 Nm (6.0 m·kg, 43 ft·lb) E
Camshaft drive gear bolt M10 1 60 Nm (6.0 m·kg, 43 ft·lb) E
Front cylinder camshaft gear bolt M10 1 40 Nm (4.0 m·kg, 29 ft·lb) E
Locknut (rocker arm adjusting

M7 4 20 Nm (2.0 m·kg, 14 ft·lb)
screw)
Valve lifter case bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Oil filter bolt M18 1 70 Nm (7.0 m·kg, 50 ft·lb)

Oil filter cartridge M20 1 17 Nm (1.7 m·kg, 12 ft·lb)
Oil pipe 1 union bolt M10 2 21 Nm (2.1 m·kg, 15 ft·lb)
Oil pipe 1 union bolt*1 M8 1 18 Nm (1.8 m·kg, 13 ft·lb)
Oil pipe 1 union bolt*2 M8 1 17 Nm (1.7 m·kg, 12 ft·lb)
Oil filter bracket bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Oil pipe bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Oil delivery pipe 2 bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Engine oil pump driven gear
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
stopper bolt
Oil pipe 3 bolt M6 5 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pump bolt (crankcase) M8 3 24 Nm (2.4 m·kg, 17 ft·lb)
2-21
TIGHTENING TORQUES
Thread
size
Oil pump housing cover 1 screw
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
(crankcase)
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
(crankcase)
Throttle body joint clamp screw M5 2 3 Nm (0.3 m·kg, 2.2 ft·lb)
Pressure regulator bolt M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Intake manifold assembly bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel pipe bolt M12 2 30 Nm (3.0 m·kg, 22 ft·lb)
Rear exhaust pipe joint nut M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe, rear exhaust
pipe joint cover and rear exhaust M8 2 24 Nm (2.4 m·kg, 17 ft·lb)
pipe joint nut
Front exhaust pipe nut M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Front exhaust pipe and rear ex-
M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
haust pipe bolt
Rear exhaust pipe and muffler
M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
bolt
Locknut (EXUP cable) M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
EXUP valve pulley cover bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear exhaust pipe joint cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Muffler and frame bolt*2 M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Muffler and muffler bracket bolt*1 M8 3 29 Nm (2.9 m·kg, 21 ft·lb)
Muffler and muffler bracket bolt*2 M8 2 29 Nm (2.9 m·kg, 21 ft·lb) LT
Muffler bracket and frame bolt M10 2 53 Nm (5.3 m·kg, 38 ft·lb) LT
O2 sensor M18 1 44 Nm (4.4 m·kg, 32 ft·lb)

Crankcase stud bolt M12 8 See NOTE. E
Crankcase bolt M6 21 10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankcase bolt M8 3 24 Nm (2.4 m·kg, 17 ft·lb)
Oil baffle plate bolt (left crank-
M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
case)
Crankcase stud bolt*1 M10 1 See NOTE. E
Crankcase stud bolt*2 M10 1 15 Nm (1.5 m·kg, 11 ft·lb) E
Nozzle M6 4 0.5 Nm (0.05 m·kg, 0.36 ft·lb)

Oil gallery screw M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Bearing housing bolt (torque lim-

M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
iter)
Oil gallery bolt M8 4 20 Nm (2.0 m·kg, 14 ft·lb) LT
Engine oil drain bolt (crankcase) M14 2 43 Nm (4.3 m·kg, 31 ft·lb)

Stator coil lead holder screw M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
2-22
TIGHTENING TORQUES
Thread
size
Crankshaft position sensor lead
M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
holder screw
Clutch cover damper plate screw M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
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) LT
Engine oil filler plug M20 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft sprocket cover plate
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
bolt
Oil baffle plate bolt (right crank-
M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
case)
Clutch cover plate bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Generator cover bolt M6 10 10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft sprocket cover bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch cover bolt M6 18 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil gallery bolt*1 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil gallery bolt*2 M6 2 8 Nm (0.8 m·kg, 5.8 ft·lb)
Clutch cover damper plate bolt M5 3 5 Nm (0.5 m·kg, 3.6 ft·lb)
Clutch cover damper bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Starter clutch bolt M8 6 24 Nm (2.4 m·kg, 17 ft·lb) LT
Generator rotor bolt M12 1 80 Nm (8.0 m·kg, 58 ft·lb) E
Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Primary drive gear bolt*1 M12 1 100 Nm (10.0 m·kg, 72 ft·lb) E
Primary drive gear bolt*2 M12 1 85 Nm (8.5 m·kg, 51 ft·lb) E
Stake
Clutch boss nut M20 1 105 Nm (10.5 m·kg, 75 ft·lb)
E
Clutch spring plate retainer bolt M6 6 8 Nm (0.8 m·kg, 5.8 ft·lb)

Bleed screw (clutch release cylin-
M8 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
der)
Clutch release cylinder bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive axle bearing retainer screw M8 2 20 Nm (2.0 m·kg, 14 ft·lb) Stake
Main axle bearing retainer
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
screw*1
Main axle bearing retainer
M6 2 12 Nm (1.2 m·kg, 8.7 ft·lb) LT
screw*2
Engine oil drain bolt (oil tank) M14 1 43 Nm (4.3 m·kg, 31 ft·lb)
Transfer gear oil drain bolt M8 1 18 Nm (1.8 m·kg, 13 ft·lb)
Stake
Middle drive gear nut M22 1 140 Nm (14.0 m·kg, 100 ft·lb)
E
Transfer gear case oil pump as-

M10 1 40 Nm (4.0 m·kg, 29 ft·lb)
sembly nut
2-23
TIGHTENING TORQUES
Thread
size
Transfer gear case oil pump as-
M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
sembly bolt
Oil pump housing screw (transfer
M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
gear case)
Transfer gear oil check bolt M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Transfer gear case bolt M10 4 50 Nm (5.0 m·kg, 36 ft·lb)
Dipstick joint bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Drive pulley case bolt M12 8 70 Nm (7.0 m·kg, 50 ft·lb)

Oil strainer bolt (oil tank) M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Oil pipe 5 bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Transfer gear case cover plate

M6 3 5 Nm (0.5 m·kg, 3.6 ft·lb)
bolt
Transfer gear case cover bolt M6 12 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil tank cover bolt M6 15 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil tank bracket bolt M8 2 28 Nm (2.8 m·kg, 20 ft·lb)
Shift shaft spring stopper bolt M8 1 22 Nm (2.2 m·kg, 16 ft·lb) LT
Stopper lever bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Crankshaft position sensor screw M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Neutral switch screw M6 2 4 Nm (0.4 m·kg, 2.9 ft·lb) LT
Stator coil screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Neutral switch lead clamp screw M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Speed sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Oil cooler bolt*1 M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Oil cooler bracket bolt*1 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Oil cooler hose bolt*1 M6 8 7 Nm (0.7 m·kg, 5.1 ft·lb)
Clutch hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Clutch pipe union bolt M10 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch pipe holder bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Clutch pipe joint nut M10 1 19 Nm (1.9 m·kg, 13 ft·lb)

*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 installed length is 141.5 mm (5.57 in).
• Install the crankcase stud bolts (M10) so that their installed length is 70.5 mm (2.78 in).
2-24
TIGHTENING TORQUES
Cylinder head tightening sequence:
A B
1 4
3 2
3 2
1 4
A. Front cylinder
B. Rear cylinder
2-25
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting bolt (left upper
M12 2 66 Nm (6.6 m·kg, 48 ft·lb) LT
side)
Engine mounting bolt (right upper
M12 2 59 Nm (5.9 m·kg, 43 ft·lb)
side)*1, 2
Engine mounting bolt (right upper
M12 2 66 Nm (6.6 m·kg, 48 ft·lb)
side)*3
Engine mounting nut (rear upper
M12 1 98 Nm (9.8 m·kg, 71 ft·lb)
side)
Engine mounting spacer bolt M18 1 18 Nm (1.8 m·kg, 13 ft·lb)
Engine bracket bolt (left upper
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine bracket bolt (right upper
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine bracket nut (rear upper
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine mounting nut (front upper
M12 1 98 Nm (9.8 m·kg, 71 ft·lb)
side)
Engine mounting nut (rear lower
M12 1 98 Nm (9.8 m·kg, 71 ft·lb)
side)
Engine mounting nut (front lower
M12 1 105 Nm (10.5 m·kg, 75 ft·lb) E
side)*1, 2
Engine mounting nut (front lower
M12 1 90 Nm (9.0 m·kg, 65 ft·lb) E
side)*3
Engine bracket nut (front upper
M10 4 53 Nm (5.3 m·kg, 38 ft·lb)
side)
Engine cross-member bracket
M8 2 30 Nm (3.0 m·kg, 22 ft·lb) LT
bolt
Engine bracket nut (rear lower
M10 3 58 Nm (5.8 m·kg, 42 ft·lb)
side)
Engine bracket bolt (right rear
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
lower side)
Transfer gear case bracket and
M10 2 63 Nm (6.3 m·kg, 45 ft·lb)
transfer gear case bolt
Transfer gear case bracket and
M10 2 53 Nm (5.3 m·kg, 38 ft·lb)
frame bolt
Cylinder-#1 ignition coil bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Cylinder-#2 ignition coil bolt*1, 2 M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Cylinder-#2 ignition coil bolt*3 M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Lean angle sensor bolt*1, 2 M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb)

Lean angle sensor bolt*3 M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb) LT
Horn bolt*1, 2 M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

Horn 1 bolt*3 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
2-26
TIGHTENING TORQUES
Thread
size
Horn 2 bolt*3 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
ISC (idle speed control) unit bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
ISC (idle speed control) unit
M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
bracket bolt
Pivot shaft nut M18 1 125 Nm (12.5 m·kg, 90 ft·lb)
Relay arm nut (relay arm and
M12 1 59 Nm (5.9 m·kg, 43 ft·lb)
swingarm)
Relay arm nut (relay arm and
M12 1 59 Nm (5.9 m·kg, 43 ft·lb)
connecting arm)
Rear shock absorber assembly
M10 1 40 Nm (4.0 m·kg, 29 ft·lb)
nut (rear side)
Rear shock absorber assembly
M12 1 59 Nm (5.9 m·kg, 43 ft·lb)
nut (front side)
Upper drive belt cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Lower drive belt cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake hose guide bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Upper bracket pinch bolt*1, 2 M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Upper bracket pinch bolt*3 M8 4 19 Nm (1.9 m·kg, 13 ft·lb)

Headlight cover bolt*1, 2 M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Headlight bracket and throttle ca-
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
ble guide bolt*1, 2
Headlight body bolt*1, 2 M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
Headlight body bolt*3 M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Headlight bracket bolt*3 M8 4 16 Nm (1.6 m·kg, 11 ft·lb)
Headlight body and headlight
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
bracket bolt*3
Main switch cover bracket bolt*3 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Main switch cover bolt*3 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Main switch and cable guide

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
bolt*3
Front turn signal/position light
M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
bolt*3
Front turn signal/position light
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
pinch nut*3
Air temperature sensor bracket
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt*3
Steering stem nut*1, 2 M28 1 115 Nm (11.5 m·kg, 85 ft·lb)
Steering stem bolt*3 M20 1 165 Nm (16.5 m·kg, 120 ft·lb) LS
Upper handlebar holder bolt M8 4 28 Nm (2.8 m·kg, 20 ft·lb)

Lower ring nut (initial tightening See
M30 1 52 Nm (5.2 m·kg, 37 ft·lb)
torque) NOTE.
2-27
TIGHTENING TORQUES
Thread
size
Lower ring nut (final tightening See
M30 1 18 Nm (1.8 m·kg, 13 ft·lb)
torque) NOTE.
Hose guide and lower handlebar
M10 2 32 Nm (3.2 m·kg, 23 ft·lb)
holder nut*1, 2
Hose guide and lower handlebar
M12 2 40 Nm (4.0 m·kg, 29 ft·lb)
holder nut*3
Front brake master cylinder hold-
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
er bolt
Front brake hose union bolt (front
M10 1 30 Nm (3.0 m·kg, 22 ft·lb)
brake master cylinder side)
Clutch master cylinder holder bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Grip end M16 2 23 Nm (2.3 m·kg, 17 ft·lb)
Lower handlebar holder nut*1, 2 M10 2 50 Nm (5.0 m·kg, 36 ft·lb) LT
Upper bracket cover bolt*1, 2 M8 2 19 Nm (1.9 m·kg, 13 ft·lb) LT
Upper bracket cover bolt*1, 2 M8 2 16 Nm (1.6 m·kg, 11 ft·lb) LT
Front brake hose guide and front

brake hose guide bracket bolt*1, M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
2
Front brake hose holder and front
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
brake hose holder bracket bolt*3
Front brake hose guide and lower
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
bracket bolt*1, 2
Front brake hose guide and lower
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
bracket bolt*3
Front brake hose joint bolt*1, 2 M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Plate bolt (front brake hose

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
joint)*3
Front brake hose joint bolt*3 M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front brake hose joint holder
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt*3
Lower bracket cover bolt*3 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Bolt (lower bracket hole)*1, 3 M8 2 16 Nm (1.6 m·kg, 11 ft·lb)

Front fender stay bolt*1, 2 M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Front fender bolt M8 6 16 Nm (1.6 m·kg, 11 ft·lb) LT
Fuel sender bolt M5 4 4 Nm (0.4 m·kg, 2.9 ft·lb)

Fuel tank bracket bolt (front side) M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Fuel tank bracket 2 bolt (front
M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
side)*3
Fuel tank bracket nut (rear side) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Sub-fuel tank bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rider seat bracket bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb) LT
2-28
TIGHTENING TORQUES
Thread
size
Fuel tank and fuel tank bracket
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt (front side)
Fuel tank and fuel tank bracket
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
bolt (rear side)
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 holder bolt*1, 2 M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel return pipe holder bolt*3 M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Fuel tank breather/overflow pipe

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
holder bolt*3
Air filter case bracket bolt*1, 2 M8 3 16 Nm (1.6 m·kg, 11 ft·lb)
Air filter case bracket bolt*3 M8 1 17 Nm (1.7 m·kg, 12 ft·lb)
For Cali-
Canister bolt*1, 2 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) fornia
only
For Cali-
fornia
Canister bolt*3 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) only
LT
Front wheel axle M18 1 72 Nm (7.2 m·kg, 52 ft·lb)

Front wheel axle pinch bolt M8 1 23 Nm (2.3 m·kg, 17 ft·lb)
Rear wheel axle nut M18 1 150 Nm (15.0 m·kg, 110 ft·lb)
Locknut (drive belt adjusting bolt) M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Front brake caliper bolt M10 4 40 Nm (4.0 m·kg, 29 ft·lb)
Front brake hose union bolt (front
M10 2 32 Nm (3.2 m·kg, 23 ft·lb)
brake caliper side)
Rear brake caliper bolt M10 2 27 Nm (2.7 m·kg, 19 ft·lb) S
Front brake disc bolt*1, 2 M6 12 23 Nm (2.3 m·kg, 17 ft·lb) LT
Front brake disc bolt*3 M8 10 23 Nm (2.3 m·kg, 17 ft·lb) LT
Rear brake disc bolt M6 6 18 Nm (1.8 m·kg, 13 ft·lb) LT
Bleed screw (front brake caliper) M8 2 6 Nm (0.6 m·kg, 4.3 ft·lb)

Bleed screw (rear brake caliper) M7 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
Rear wheel pulley nut M12 5 95 Nm (9.5 m·kg, 68 ft·lb)
Left side cover and sub-fuel tank
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
bracket bolt
Left side cover bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Seat lock cable assembly bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Lead holder bracket bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Right side cover bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Starter motor lead bolt (starter

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
relay side)*1, 2
2-29
TIGHTENING TORQUES
Thread
size
Positive battery lead bolt (starter
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
relay side)*1, 2
Starter motor lead bolt (starter
M6 1 5 Nm (0.5 m·kg, 3.6 ft·lb)
relay side)*3
Positive battery lead bolt (starter
M6 1 5 Nm (0.5 m·kg, 3.6 ft·lb)
relay side)*3
Rear fender bracket and frame
M10 4 40 Nm (4.0 m·kg, 29 ft·lb)
bolt
Rear fender bracket and frame
M10 2 40 Nm (4.0 m·kg, 29 ft·lb) LT
bolt*1, 2
Rear fender bracket and rear
M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
fender bolt
Passenger seat bolt M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Rider seat bracket assembly and
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
seat lock assembly bolt
Tool kit and battery box bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Pressure regulator bracket
M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
bolt*1, 2
Pressure regulator bracket bolt*3 M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Cylinder-#1 ignition coil cover
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
bolt*1, 2
Cylinder-#1 ignition coil bracket
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt*1, 2
Right ignition coil cover bolt*3 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Right ignition coil bracket bolt*3 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

License plate bolt*1, 2 M8 3 16 Nm (1.6 m·kg, 11 ft·lb)
Sidestand bolt M10 2 63 Nm (6.3 m·kg, 45 ft·lb) LT
Rider footrest assembly bolt (left

M10 4 48 Nm (4.8 m·kg, 35 ft·lb) LT
and right)
Passenger footrest bolt (left and
M10 4 48 Nm (4.8 m·kg, 35 ft·lb) LT
right)
Rear brake master cylinder
bracket and rear brake master M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
cylinder bolt
Rear brake master cylinder
M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
bracket and frame bolt
Rear brake master cylinder cover
M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
bolt
Brake fluid reservoir and frame
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Rear brake hose holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Shift pedal shaft bracket bolt*1, 2 M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
2-30
TIGHTENING TORQUES
Thread
size
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 ft·lb)
Lower bracket pinch bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Cap bolt M43 2 23 Nm (2.3 m·kg, 17 ft·lb)
Damper rod assembly M12 2 40 Nm (4.0 m·kg, 29 ft·lb) LT
Lower front fork cover nut*1, 2 M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Stake
Drive pulley nut M22 1 140 Nm (14.0 m·kg, 100 ft·lb)
E
Drive pulley cover damper plate

M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
screw
Drive pulley cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rectifier/regulator cover bolt M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)
Lead cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rectifier/regulator bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive pulley cover plate bolt M6 3 5 Nm (0.5 m·kg, 3.6 ft·lb)
Wire harness guide bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Throttle cable guide bolt (upper

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
side)*1, 2
Throttle cable guide bolt (lower
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
side)*1, 2
Throttle cable guide bolt*3 M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear shock absorber locknut M50 1 30 Nm (3.0 m·kg, 22 ft·lb)
Windshield holder bracket as-
M8 4 30 Nm (3.0 m·kg, 22 ft·lb)
sembly bolt*2
Windshield holder nut*2 M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Windshield bracket brace nut*2 M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Windshield brace nut*2 M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)
Windshield lock nut*2 M24 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Windshield lock cover nut*2 M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Backrest upper bracket and back-
M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
rest lower bracket bolt*2
Backrest pad and backrest up-
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
per bracket bolt*2
Backrest pad and backrest up-
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
per bracket stay bolt*2
Backrest lock nut*2 M24 1 12 Nm (1.2 m·kg, 8.7 ft·lb)
Passenger footrest and sidebag
M10 4 47 Nm (4.7 m·kg, 34 ft·lb) LT
bracket bolt (left and right)*2
2-31
TIGHTENING TORQUES
Thread
size
Sidebag bracket bolt*2 M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Sidebag bracket brace nut*2 M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
*1 For XV19S(C)/ XV19M(C)
*2 For XV19CTS(C)/ XV19CTM(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 (1.8 m·kg, 13 ft·lb) with a torque wrench.
2-32
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
O-rings LS
Bearings E
Cylinder head nuts and washers E
Connecting rod small end and big end E
Crankshaft journals M
Piston surfaces E
Piston pins E
Connecting rod bolts M
Balancer idle gear inner surface and balancer idle gear shaft E
Left balancer driven gear inner surface M
Right balancer M
Gasket (left balancer driven gear housing) LS
Flange bolts (left balancer drive gear and right balancer driven gear) E
Camshaft cam lobes and camshaft journals M
Flange bolt (camshaft gear) E
Valve push rod end balls E
Valve stems (intake and exhaust) M
Valve stem ends (intake and exhaust) E
Valve lifters E
Rocker arms E
Rocker arm shafts E
Camshaft (front and rear cylinders) E
Oil pump rotors (inner and outer) and oil pump housing LS
Oil pump driven gear shaft E
Crankcase stud bolt ends E
Starter clutch idle gear shaft E
Starter clutch idle gear inner surface E
Starter clutch gear inner surface and outer surface E
Generator shaft journal E
Primary driven gear inner surface E
Clutch push rods and ball LS
Clutch boss nut and washer E
2-33

Transmission gears (wheel and pinion) and collar M
Drive pulley nut and conical spring washer E
Middle drive gear nut and conical spring washer E
Shift forks and shift fork guide bars E
Shift drum E
Shift shaft and shift shaft oil seal LS
Shift fork pawl M
Yamaha bond
Crankcase mating surface No.1215 (Three Bond
No.1215®)
Yamaha bond
Stator coil lead grommet No.1215 (Three Bond
No.1215®)
Yamaha bond
Crankshaft position sensor lead grommet No.1215 (Three Bond
No.1215®)
2-34
EAS20380
CHASSIS
Steering bearings and upper bearing dust cover lip LS
Lower bearing dust seal lip LS
Lower bracket steering shaft*1 LS
Steering stem bolt*1 LS
Front wheel oil seal lips (left and right) LS
Rear wheel oil seal lips LS
Rear wheel drive hub oil seal lip LS
Rear wheel drive hub mating surface LS
Tube guide (throttle grip) inner surface and throttle cables LS
Brake lever pivoting point and metal-to-metal moving parts S
Clutch lever pivoting point and metal-to-metal moving parts S
Brake pedal shaft pivoting point LS
Shift pedal pivoting point LS
Passenger footrest pivoting point and ball LS
Sidestand pivoting point and metal-to-metal moving parts LS
Dowel pins (rear fender stay) LS
Pivot shaft LS
Swingarm pivoting point, collar flange circumference, and oil seal inner
LS
surface
Rear shock absorber bushings and O-rings LS
Swingarm, relay arm bearings, and oil seal lips LS
Connecting arm bushings and O-rings LS
Rear wheel axle LS
Clutch master cylinder push rod pin and contact surface S
2-35
2-36
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390

EAS20400
ENGINE OIL LUBRICATION CHART
22 21 20 23
19 18
17
16
15 9
8
14
11
14
9
10 12
13
8 7
2
3
2-37
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 lifter case
13. Front valve lifter case
14. Push rod
15. Crankshaft
16. Camshaft sprocket cover
17. Generator shaft
18. Generator cover
19. Left crankcase
20. Oil filter cartridge bracket
21. Oil filter cartridge
22. Right crankcase
23. Oil cooler (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C))
2-38
EAS20410
LUBRICATION DIAGRAMS
2 9
10
A-A
B-B
3
A 4
B
D
A
1
B
E
E
C
D
7 6 5
D-D C
11
E-E
2-39
1. Oil tank
2. Dipstick
3. Oil pipe 2
4. Oil delivery pipe 1
5. Oil filter cartridge
7. Oil pipe 3
8. Oil pipe 4
9. Oil pipe 5
10. Oil strainer (oil tank)
2-40
3
3
A
2 4
6
D 7
C
C
D
B
1
B-B
5
B
6
7
D-D C-C
2-41
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)
2-42
A A
A-A
2-43
1. Oil pipe 1
2. Oil pump
4. Joint pipe
2-44
1 2
4 3
2-45
1. Main axle
2. Drive axle
4. Oil pump
A. To the oil filter cartridge
2-46
1
5
B-B
B A
A
2-47
1. Oil pipe 5
2. Transfer gear oil pump
3. Oil strainer (transfer gear case)
4. Middle drive shaft
5. Oil strainer (oil tank)
A. From the oil pump
2-48
2-49
1. Transfer gear oil pump

2. Middle driven shaft
2-50
CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C))
EAS20430
CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
1 5 5 6
7
B-B C-C D-D
D
2 A 3 4 5
C
1
1 5
A E
6
B C 7
A D
C E
B D B
F
5
F
1
6
7
6 7
F-F
G
E
F
11 8
10 9
2-51
XV19CTM(C))
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 switch
11. Rear brake light switch lead
A. Cross the left and right handlebar switch leads.
Either lead can be routed on top.
B. 70 mm (2.76 in)
C. 5–25°
D. 10–30°
E. Fasten the rear brake light switch lead with the
plastic locking tie. Face the end of the plastic
locking tie inward, and then cut off the excess end
of the tie.
F. Make sure that there is no slack in the rear brake
light switch lead in the area shown in the illustration.
G. Fasten the rear brake light switch lead with the
locking tie downward, and then cut off the excess
end of the tie.
2-52
XV19CTM(C))
5 1
4 G 9
A 2 10
B
E C
3
D
G I
E
F
G 6 J
8
H
F
F 7
11
E
A 2
B
D
C B-B
1 B
D 4
1 2
12 2
8 3
6
1
K 2
3
G-G F-F D-D
L
E-E
2-53
XV19CTM(C))
1. Main switch lead
3. Wire harness
5. Air temperature sensor lead
6. Front left turn signal/position light lead
7. Headlight lead
8. Front right turn signal/position light lead
9. Headlight coupler (high beam)
10. Headlight coupler (low beam)
12. Main switch
A. View with headlight lens unit removed.
B. Place the joint coupler behind the leads.
C. Place the sections of the handlebar switch leads
that are not covered by their protective sleeves in
the rear of the headlight housing.
D. Fasten the headlight leads, front turn
signal/position light leads, and accessory light lead
with the holders along the side of the headlight
housing.
E. Place the headlight leads, front turn signal/position
light leads, and accessory light lead near the base
of the holder.
F. 30 mm (1.18 in)
G. View from rear of headlight lens unit
H. Less than 20 mm (0.79 in). Fasten the headlight
lead (low beam) with the holder, making sure to
fasten the protective sleeve of the lead, not the lead
itself.
I. Route the headlight lead (high beam) between the
headlight coupler (low beam) and the stay.
J. Route the headlight lead (high beam) behind the
headlight lead (low beam).
K. Secure the plastic band by inserting the projection
on the band into the hole in the headlight housing.
L. Face the end of the plastic band downward.
2-54
XV19CTM(C))
U U
S S
R T R T R T R T
3 10
3 4 3 20 21 11
A-A B-B C-C 4 4 D-D 3
7 8 9 G
C D
A B E
D
6 B C
5 A
4 F
3
D
2
B C
A
E H
I
J
L K
1 12
J M
Q J 13
F F
N 14
19 H
I G
18 P H
G
O 17 16 15 O
22 23 24
V
14 14 14 W
AE
H-H G-G F-F X
V 25 Y
AF
K AD 26
27 Y
AH
Z AC AB AA Z
14
AG
K 28 E
J-J I
2-55
XV19CTM(C))
1. EXUP servo motor J. Fasten the wire harness and the cylinder-#2 left
2. Fuse box and right spark plug leads with a plastic locking tie,
making sure to install the tie just past the end of the
3. Wire harness protective tube of the wire harness. Face the end of
4. Fuel outlet hose the plastic locking tie inward, and then cut off the
5. Cylinder-#1 right spark plug cap excess end of the tie.
6. Cylinder-#1 right ignition coil K. To the throttle position sensor
7. Cylinder-#2 intake air pressure sensor coupler L. To the fuel injector and engine temperature sensor
8. Fuel sender (fuel tank) coupler M. To the neutral switch
9. Meter assembly coupler N. To the speed sensor
10. Throttle cable O. Fasten the stator coil lead with the plastic locking
ties. Face the end of each plastic locking tie
11. Front brake hose outward, and then cut off the excess end of the tie.
12. Cylinder-#2 right spark plug cap P. To the rear brake caliper
13. Cylinder-#1 left ignition coil Q. Install the O2 sensor coupler completely onto the
14. Clutch pipe O2 sensor bracket.
15. Neutral switch lead R. Outside of the frame
16. Stator coil lead S. Position the buckle of the plastic locking tie to the
17. Speed sensor lead inside of the frame. Face the end of the plastic
18. O2 sensor lead locking tie upward, and then cut off the excess end
of the tie.
19. EXUP cable
T. Inside of the frame
20. Cylinder-#1 right spark plug lead
U. Position the buckle of the plastic locking tie to the
21. Cylinder-#1 left spark plug lead inside of the frame.
22. ISC (idle speed control) unit inlet hose V. To the wire harness
23. Cylinder-#2 ISC (idle speed control) unit outlet W. To the cylinder-#2 right spark plug
hose
X. Right side
24. Cylinder-#1 ISC (idle speed control) unit outlet
hose Y. Position the sub-wire harness 3 coupler and the
sub-wire harness 4 coupler between the cylinder-
25. Sub-wire harness 3 coupler #2 right spark plug lead and the cylinder-#1 ISC
26. Cylinder-#2 right spark plug lead unit outlet hose.
27. Sub-wire harness 4 coupler Z. Face the ends of the hose clamp outward, angled
28. Cylinder-#2 left spark plug lead 45° downward.
A. Fasten the cylinder-#1 left and right spark plug AA.Route the cylinder-#2 right spark plug lead under
leads, fuel outlet hose, wire harness and the fuel the sub-wire harness 4.
tank damper with the plastic locking tie. Install the AB.Face the ends of the hose clamp downward.
plastic locking tie in the rear slot of the fuel tank AC.Route the cylinder-#2 left spark plug lead under the
damper. cylinder-#2 ISC unit outlet hose.
B. Fasten the fuel outlet hose, wire harness, and fuel AD.Left side
tank damper with the plastic locking tie. Install the
plastic locking tie in the front slot of the fuel tank AE.To the cylinder-#2 left spark plug
damper and make sure that the end of the damper AF. Install the clutch pipe onto the clutch release
is aligned with the edge of the flat section on the cylinder, making sure that the pipe contacts the
outside of the frame. projection on the cylinder.
C. Fasten the cylinder-#1 left and right ignition coil AG.To the O2 sensor
leads, engine temperature sensor lead, and throttle AH.Align the cutout in the clutch pipe union bolt cap
position sensor lead to the guide on the engine with the projection on the clutch release cylinder.
bracket (right upper side) with the plastic locking tie.
Face the end of the plastic locking tie rearward, and
then cut off the excess end of the tie.
D. Fasten sub-wire harness 2 with the plastic locking
tie.
E. Align the positioning tape on the wire harness with
the top of the frame.
F. 0–15 mm (0–0.59 in)
G. Route the throttle cables behind the front brake
hose.
H. Make sure that the wire harness is not twisted
between the fuel tank and the headlight assembly.
I. Position the cylinder-#2 left and right spark plug
leads, sub-wire harness 2 coupler and sub-wire
harness 4 coupler on top of the guide.
2-56
XV19CTM(C))
D
C
A B A B 2 3 4 5
E
A
B
F
6 G
21 H
G G
C F
C
20
22
19 7
18 U 8
T I
D J
17 9
S
P D E
R 16 Q 15 O N 14 N M 13 12 L 11 K 10
26 27 28 29 30 31 32 24
AB 18 15 16 25
23
33
D-D
AA H
H 24 V
A-A
AC AA X W 3
2
AD
1
Z Y
E
36 F
B-B
34 1
16 15
D
35 18
S G-G
Q D C-C
R O
2-57
XV19CTM(C))
1. Clutch hose K. Fasten the stator coil lead and rectifier/regulator
2. Throttle cable (decelerator cable) lead with the plastic locking tie. Face the end of the
plastic locking tie outward, and then cut off the
3. Throttle cable (accelerator cable) excess end of the tie.
4. Cylinder-#2 left spark plug cap L. Fasten the lean angle sensor lead, starter motor
5. Cylinder-#1 left spark plug cap lead, horn 1 lead, rear brake light switch lead, and
6. Sub-wire harness 1 sidestand switch lead with the holder.
7. Rectifier/regulator M. Route the starter motor lead, horn 1 lead, rear
brake light switch lead, and sidestand switch lead to
8. Crankshaft position sensor lead the inside of the frame boss.
9. Stator coil lead N. Fasten the starter motor lead, horn 1 lead, rear
10. Rectifier/regulator lead brake light switch lead, and sidestand switch lead
11. Lean angle sensor with the plastic locking tie. Face the end of the
plastic locking tie outward, and then cut off the
12. Horn 2 lead excess end of the tie.
13. Horn 2 O. Fasten the starter motor lead, horn 1 lead, and rear
14. Sidestand switch brake light switch lead with the plastic locking tie,
15. Horn 1 lead and then face the end of the tie outward. Be sure to
install the plastic locking tie behind the frame cross
16. Rear brake light switch lead member and to fasten the rear brake light switch
17. Horn 1 lead at the white tape.
18. Starter motor lead P. Route the starter motor lead, horn 1 lead, and rear
19. Clutch pipe brake light switch lead along the frame in the area
shown in the illustration, making sure not to cross
20. Fuel tank breather/overflow hose the leads.
21. Rollover valve Q. Align the positioning tape on the starter motor lead
22. Front brake hose with the engine mounting bolt (front lower side).
23. Headlight assembly R. Pass the fuel tank breather/overflow hose through
24. Front fork the horn 1 bracket, making sure to position the end
of the hose as shown in the illustration.
25. Frame
S. Fasten the starter motor lead, horn 1 lead, and rear
26. Main fuse brake light switch lead with the plastic locking tie,
27. Diode 1 and then face the end of the tie inward.
28. Relay unit T. Fasten the horn 1 lead, rear brake light switch lead,
29. Turn signal relay and starter motor lead with the plastic locking tie.
Face the end of the plastic locking tie inward, and
30. Headlight relay then cut off the excess end of the tie.
31. Starter relay U. Route the horn 1 lead to the rear of the starter
32. EXUP servo motor motor lead.
33. EXUP cable V. Pass the throttle cables through the cable guides
34. Speed sensor lead as shown in the illustration.
35. Wire harness W. Install the lead cover, making sure not to pinch the
stator coil lead and rectifier/regulator lead.
36. Canister
X. Pass the plastic locking tie through the hole in the
A. Route the throttle cables to the inside of the clutch battery box projection, and then fasten the wire
hose. harness with the tie.
B. Pass the cylinder-#2 left spark plug lead through Y. Fasten the stator coil lead at the white tape with the
the guide. plastic locking tie.
C. 30–40 mm (1.18–1.57 in) Z. Fasten the stator coil lead with the plastic locking
D. Position the buckle of the plastic locking tie to the ties.
inside of the frame. AA.Pass the plastic locking tie through the hole in the
E. Fasten the crankshaft position sensor lead, neutral battery box projection, and then fasten the wire
switch lead, and sidestand switch lead with the harness with the tie.
holders. AB.Route the wire harness along the side of the fuse
F. Fasten the starter motor lead, speed sensor lead, box/starter relay bracket.
and wire harness with the holders. AC.For California only
G. Route sub-wire harness 1 to the inside of the AD.Route the horn 1 lead to the rear of the canister.
frame.
H. To the tail/brake light
I. Fasten the starter motor lead, horn 1 lead, rear
brake light switch lead, sidestand switch lead, and
crankshaft position sensor lead with the plastic
locking tie.
J. Make sure that there is no slack in the stator coil
lead and rectifier/regulator lead in the area shown
in the illustration.
2-58
XV19CTM(C))
16 17
L
1 15
A
8 18 4
A-A B-B
14
E E
13 A A
B M
3
K
12
C
J D
I E
4 C
F
D G
D E
15 22 4
23
H B B 21
5
6 N
17
11
7 24 19
18 O
25 16 8 20
10
C 9 8 E-E D-D
W U P
X
28
Y
V 5 Q
27
26
T 9 S R
2-59
XV19CTM(C))
1. Meter assembly coupler L. Fasten the air filter case damper with the plastic
2. Cylinder-#2 intake air pressure sensor coupler locking tie so that the rubber part of the damper
contacts the frame. Be sure to pass the plastic
3. Cylinder-#1 right spark plug cap locking tie between the air filter case damper and
4. Wire harness the frame.
5. Negative battery lead M. Route the crankshaft position sensor lead,
6. EXUP servo motor sidestand switch lead, neutral switch lead, starter
motor lead, and speed sensor lead under the fuel
7. Fuse box outlet hose.
8. Starter motor lead N. Inside of frame
9. Positive battery lead O. Outside of frame
10. Sub-wire harness 1 P. View with tray removed
11. ECU (electronic control unit) Q. Route the negative battery lead under the starter
12. Cylinder-#1 left spark plug cap motor lead and battery positive lead.
13. Cylinder-#1 intake air pressure sensor coupler R. Route the positive battery lead (main fuse to starter
14. Fuel sender (fuel tank) coupler relay) over the tray.
15. Neutral switch lead S. Route the negative battery lead towards the front of
the vehicle.
16. Sidestand switch lead
T. Route the positive battery lead (battery to starter
17. Crankshaft position sensor lead relay) under the tray.
18. Speed sensor lead U. View with tray installed
19. Fuel hose (fuel tank to fuel hose joint) V. To the tail/brake light
20. Fuel return hose (fuel return pipe to sub-fuel tank) W. View with ECU removed
21. Air vent hose (fuel pump to fuel hose joint) X. Wrap the protective covering around the couplers
22. Fuel outlet hose (crankshaft position sensor coupler, auxiliary DC
23. Frame jack coupler, neutral switch coupler, sub-wire
harness 1 coupler, speed sensor coupler, and
24. Oil tank sidestand switch coupler) and the wire harness.
25. Sub-fuel tank Y. When installing the ECU, be sure not to pinch the
26. Battery leads in the areas shown in the illustration with
27. Main fuse oblique lines.
28. Fuel pump lead
A. Do not pinch the leads between the fuel tank
bracket and the frame when installing the bracket.
B. Pass the plastic locking ties through the holes in
the frame damper, and then fasten the wire harness
and damper with the ties. Face the end of each
plastic locking tie upward, and then cut off the
excess end of the tie.
C. Align the white tape on the wire harness with the
frame cross member.
D. 20 mm (0.79 in)
E. Fasten the wire harness with the plastic locking tie.
Face the end of the plastic locking tie upward, and
F. Route the wire harness along the frame.
G. Fasten the wire harness with the plastic locking tie,
making sure to align the tie with the line on the
rubber damper. Face the end of the plastic locking
tie upward, and then cut off the excess end of the
tie.
H. Connect the ECU couplers, and then fasten the
ECU with the band.
I. Fasten the fuel return hose (fuel return pipe to sub-
fuel tank) with the plastic locking tie. Face the end
of the plastic locking tie inward, and then cut off the
J. Route the cylinder-#1 intake air pressure sensor
lead so that it does not protrude past the top of the
frame.
K. Fasten the fuel tank damper with the plastic locking
tie. Install the plastic locking tie in the middle slot of
the fuel tank damper.
2-60
XV19CTM(C))
2
1
3
F
4
5
6
7
A
17
23
18 C B 8
12
A 9
19 D
16 15 11
22 10
G E
13
14
21
20 H 8
I
6 B
H
L M
K
J
T U
S 24
V N
R
25
5
4 P 6
Q
5
L
7
G 11 O
A 4
W F
7
21
11 8
X 26
24
27
C
C
C-C
B
28
2-61
XV19CTM(C))
1. Fuel tank breather hose Q. Install the fuel hose (fuel tank to fuel hose joint)
2. Fuel sender (fuel tank) with its white paint mark facing downward.
3. Fuel tank R. To the pressure regulator
4. Fuel hose (fuel tank to fuel hose joint) S. Install the air vent hose (fuel hose joint to fuel tank)
with its white paint mark facing downward.
5. Fuel return hose (fuel return pipe to sub-fuel tank)
T. For California only
6. Air vent hose (fuel hose joint to fuel tank)
U. To the fuel tank
7. Fuel hose joint
V. To the intake manifold assembly
8. Fuel outlet hose
W. Fasten the canister purge hose and fuel tank
9. Fuel pump breather/overflow hose with the holder, making sure
10. Sub-fuel tank to align the paint mark on the breather/overflow
11. Fuel hose (fuel hose joint to fuel pump) hose with the holder.
12. Fuel return pipe X. Fasten the canister purge hose and throttle cable
guide with the holder.
13. Fuel return hose (pressure regulator to fuel return
pipe)
14. Pressure regulator
15. Rollover valve 1
17. Cylinder-#2 left spark plug lead
18. Rollover valve hose 1
20. Starter motor lead
21. Fuel tank breather/overflow hose
24. Air vent hose (fuel pump to fuel hose joint)
25. Fuel pump coupler
26. Canister purge hose (for California only)
27. Canister (for California only)
28. Canister breather hose (for California only)
A. Align the blue paint mark on the fuel hose (fuel
hose joint to fuel tank) with the round indentation on
the bend in the fuel hose joint.
B. Face the fastener of the clamp downward, making
sure that the projections on the clamp are
positioned as shown in the illustration.
C. Align the white paint mark on the end of the fuel
return hose (fuel return pipe to sub-fuel tank) with
the white paint mark on the fuel return pipe.
D. White paint mark
E. Align the ends of the hose clamp with the white
paint mark on the fuel return hose.
F. Align the paint marks on the hoses with the hose
joint as shown in the illustration.
G. Fasten the fuel tank breather/overflow hose to the
throttle cable guide with the holder.
H. Align the paint mark on the hose with the hose joint
as shown in the illustration.
I. Fasten the fuel tank breather/overflow hose and
starter motor lead with the holder.
J. To the fuel injector
K. Align the yellow paint mark on the air vent hose
(fuel hose joint to fuel tank) with the round
indentation on the bend in the fuel hose joint.
L. Face the fastener of the clamp to the left.
M. Face the ends of the hose clamp forward.
N. Install the air vent hose (fuel pump to fuel hose
joint) with its white paint mark facing upward.
O. Face the ends of the hose clamp upward.
P. Face the fastener of the clamp upward, making
2-62
XV19CTM(C))
A
5 8 9
C 10
4 7
3 6
D E
B
A
2
1
11
12
17
13
B
H
G 14
16 13 11 15
F
18
I
C
13 13
11 11 11
C
J
C-C B
19
4
5
7 A
20
K 21
22
2-63
XV19CTM(C))
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)
8. ISC (idle speed control) unit inlet hose
10. Fuel tank breather/overflow hose (for California
only)
hose
hose
16. Fuel outlet hose
17. Cylinder head breather hose
18. Hose joint cover
20. Cylinder-#1 injector coupler
21. Engine temperature sensor coupler
22. Sub-wire harness 2
A. Face the ends of the hose clamp to the left, angled
45° rearward.
B. Install the cylinder-#1 intake air pressure sensor
hose onto the throttle body pipe up to the bend in
the pipe, making sure to face the white paint mark
on the hose upward. Face the ends of the hose
clamp forward.
C. Fasten the canister purge hose and the air filter
case breather hose 2 with the hose clamp, making
sure to face the ends of the clamp upward (for
California only).
D. Face the ends of the hose clamp to the left.
E. Fasten the canister purge hose and fuel tank
breather/overflow hose with the holder 70 mm (2.76
in) from the hose joints on the canister (for
California only).
F. Install the cylinder-#2 intake air pressure sensor
clamp rearward.
G. Install the canister purge hose onto the throttle
body pipe up to the bend in the pipe, making sure to
face the white paint mark on the hose upward (for
California only).
H. Face the ends of the hose clamp rearward, angled
to the left.
I. Align the white paint marks.
J. Align the yellow paint marks.
K. Route the canister purge hose over the air filter
case joint clamp screw.
2-64
XV19CTM(C))
2 A 3
1 A
4
5
16
E 15 9 10 B 11 B
10
9 8
14 C
7
D B
13 6
12
17
9
4
H
18
10
19
I
B
8
J
8 G
10 9
B A F
2-65
XV19CTM(C))
4. ISC (idle speed control) unit coupler
6. Rollover valve 1
7. Rollover valve 2
hose
hose
11. Hose joint
14. Throttle body assembly
17. Cylinder-#2 left ignition coil
18. Cylinder-#2 right ignition coil
A. Face the ends of the hose clamp inward.
B. Face the ends of the hose clamps outward.
C. Install the cylinder-#2 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold assembly)
completely onto the intake manifold, making sure to
face the green paint mark on the hose to the left.
Face the ends of the hose clamp outward, angled
45° forward.
D. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold assembly)
completely onto the intake manifold, making sure to
face the blue paint mark on the hose to the left.
E. Face the ends of the hose clamp upward.
F. Position the sub-wire harness 4 coupler on top of
the guide.
G. To the wire harness
H. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose onto the ISC unit pipe, making sure to
align the blue paint mark on the hose with the blue
paint mark on the pipe.
I. Install the ISC (idle speed control) unit inlet hose
onto the ISC unit pipe, making sure to align the
white paint mark on the hose with the white paint
mark on the pipe.
J. Install the cylinder-#2 ISC (idle speed control) unit
align the green paint mark on the hose with the
green paint mark on the pipe.
2-66
CABLE ROUTING (for XV19CS(C)/ XV19C(C))
EAS1D77001
3
2
F
E
1 E
A 4
E E
A B-B C-C D
2 3
C
5 6
3
B
G E-E F-F
B
5
A C 6
1
4
A B D
1
F
4 F
D
C
10
9 8
2-67
1. Clutch hose
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
A. Pass the left handlebar switch lead through the
grommet.
B. 5–15 mm (0.20–0.59 in)
C. Fasten the rear brake light switch lead with a
locking tie inward, and then cut off the excess end
of the tie.
D. Fasten the rear brake light switch lead with a
locking tie downward, and then cut off the excess
end of the tie.
E. 15–35°
F. Pass the right handlebar switch lead through the
cutouts in the lead holder.
G. Do not pinch the right handlebar switch lead.
2-68
B B
A 2
3
1
7
A
E
D
C
5 4
A
C
G
F
H 7 1
D 8
F F
9
L
10 F
F
E
M
K
H
J I E
11
C
7
1 O
D 3 N E-E F-F
2-69
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
9. Main switch
A. Position the main switch coupler in the rear of the
headlight housing.
B. Fasten the wire harness at the white tape with the
holder.
C. Position the accessory light coupler and joint
coupler in front of the plate.
D. Fasten the main switch lead with the holder.
E. Fasten the front left turn signal/position light lead,
front right turn signal/position light lead, and joint
coupler lead with the holder.
F. Fit the right handlebar switch lead in between the
grommet and the main switch cover bracket,
making sure to push the lead all the way down.
G. Route the main switch lead under the headlight
bracket.
H. Pass the left and right handlebar switch leads
through the cutouts in the main switch cover.
I. Pass the left and right handlebar switch leads
between the cable guide and the upper bracket.
J. Fit the left handlebar switch lead in between the
grommet and the main switch cover bracket,
making sure to push the lead all the way down.
K. Fit the right handlebar switch lead in between the
main switch and the cable guide, making sure to
push the lead all the way in.
L. Route the right handlebar switch lead along the
grommet.
M. Pass the front left turn signal/position light lead
through the lead guide.
N. Route the main switch lead behind the plate.
O. Bend the projection on the lead guide to fasten the
front right turn signal/position light lead.
2-70
10 H
11
G
E F F
D 7 8 9
6
B I
C
4
5 DE
3 BC J
A 1 2 K
E
A C D
B
L
N M 12
A
13
P
19
R Q
18 14
O O O
17 16 15
3 U U
T T
S S
19
4 3
A-A B-B C-C
V
V
T
T
3
S S
3
20 4 4
D-D E-E
2-71
1. EXUP servo motor P. To the neutral switch

2. Fuse box Q. To the speed sensor
3. Wire harness R. Pass the O2 sensor lead through the cutout in the
4. Fuel outlet hose heat protector.
5. Cylinder-#1 right spark plug cap S. Outside of the frame
6. Cylinder-#1 right ignition coil T. Inside of the frame
7. Cylinder-#2 intake air pressure sensor coupler U. Position the buckle of the plastic locking tie to the
8. Fuel sender (fuel tank) coupler inside of the frame. Face the end of the plastic
locking tie upward, and then cut off the excess end
9. Meter assembly coupler of the tie.
10. Front brake hose V. Position the buckle of the plastic locking tie to the
11. Front turn signal/position light lead inside of the frame.
12. Cylinder-#2 right spark plug cap
13. Cylinder-#2 right ignition coil
15. Neutral switch lead
16. Stator coil lead
17. Speed sensor lead
18. EXUP cable
19. O2 sensor lead
20. Cylinder-#1 right spark plug lead
A. Fasten the sub-wire harness with the holder.
B. Fasten the cylinder-#1 right spark plug lead, fuel
outlet hose, wire harness and the fuel tank damper
with a plastic locking tie. Install the plastic locking
tie in the rear slot of the fuel tank damper.
C. Fasten the fuel outlet hose, wire harness, and fuel
tank damper with a plastic locking tie. Install the
plastic locking tie in the front slot of the fuel tank
damper and make sure that the end of the damper
is aligned with the edge of the flat section on the
outside of the frame.
D. Fasten the wire harness to the guide on the engine
bracket (right upper side) with a plastic locking tie,
and then cut off the excess end of the tie.
E. Fasten the wire harness to the right ignition coil
bracket with a plastic locking tie.
F. Fasten the wire harness and meter assembly lead
to the frame with plastic locking ties. Face the end
of each plastic locking tie inward, and then cut off
the excess end of the tie.
G. Position the plastic locking tie to the front of the
projection on the frame.
H. Align the positioning tape on the wire harness with
the top of the frame.
I. 10 mm (0.39 in)
J. Fasten the front turn signal/position light leads to
the front brake hose with a plastic locking tie.
Position the buckle of the plastic locking tie to the
outside of the front brake hose, with the end of the
tie facing outward, and then cut off the excess end
of the tie.
K. Pass the wire harness through the guide.
L. Fasten the wire harness and cylinder-#2 right
spark plug lead to the frame with a plastic locking
tie. Face the end of the plastic locking tie
downward, and then cut off the excess end of the
tie.
M. To the throttle position sensor
N. To the fuel injectors and engine temperature
sensor
O. Fasten the stator coil lead with a plastic locking tie.
Position the buckle of the plastic locking tie to the
outside of the frame, with the end of the tie facing
downward, and then cut off the excess end of the
tie.
2-72
1
2 3
4 5
A C
E
B 4 5 D
F
6 G
7
8 H
W I
B B
21
20
A
22 V
9
19 10
U J
T
D K 11
18 Q
D C L
S
17 R P O 16 O N 15 14 M 13 12
31 23 24 25 26 27 28
AC
30 19
B-B
E 29
E AD
AB
AE
AF C AA X
33
32
19 17 Z Y
17
32
A
S
R P
D-D
2-73
1. Clutch hose J. Fasten the starter motor lead, horn 1 lead, rear
2. Throttle cable (accelerator cable) brake light switch lead, sidestand switch lead,
crankshaft position sensor lead and
3. Throttle cable (decelerator cable) rectifier/regulator lead to the frame with a plastic
4. Right handlebar switch coupler locking tie.
5. Left handlebar switch coupler K. Make sure that there is no slack in the stator coil
6. Cylinder-#1 left ignition coil lead and rectifier/regulator lead in the area shown
7. Cylinder-#1 left spark plug cap
L. Fasten the stator coil lead and rectifier/regulator
8. Sub-wire harness 1 lead with a plastic locking tie. Face the end of the
9. Rectifier/regulator plastic locking tie outward, and then cut off the
10. Crankshaft position sensor lead excess end of the tie.
11. Stator coil lead M. Fasten the lean angle sensor lead, starter motor
lead, horn 1 lead, rear brake light switch lead, and
12. Rectifier/regulator lead sidestand switch lead with the holder.
13. Lean angle sensor N. Route the starter motor lead, horn 1 lead, rear
14. Horn 2 lead brake light switch lead, and sidestand switch lead
15. Horn 2 to the inside of the frame boss.
16. Sidestand switch O. Fasten the starter motor lead, horn 1 lead, rear
brake light switch lead, and sidestand switch lead
17. Rear brake light switch lead with plastic locking ties. Face the end of the plastic
18. Horn 1 locking tie outward, and then cut off the excess end
19. Starter motor lead of the tie.
20. Cylinder-#2 left spark plug cap P. Fasten the starter motor lead, horn 1 lead, and
rear brake light switch lead with a plastic locking
21. Cylinder-#2 left ignition coil tie, and then face the end of the tie outward. Be
22. Front brake hose sure to install the plastic locking tie behind the
23. Main fuse frame cross member and to fasten the rear brake
light switch lead at the white tape.
24. Turn signal relay
Q. Route the starter motor lead, horn 1 lead, and rear
25. Relay unit brake light switch lead along the frame in the area
26. Headlight relay shown in the illustration, making sure not to cross
27. Starter relay the leads.
28. EXUP servo motor R. Align the positioning tape on the starter motor lead
with the engine mounting bolt (front lower side).
29. EXUP cable
S. Fasten the starter motor lead, horn 1 lead, and
30. Wire harness rear brake light switch lead with a plastic locking
31. Speed sensor lead tie, and then face the end of the tie inward.
32. Horn 1 lead T. Fasten the horn 1 lead, rear brake light switch
33. Canister lead, and starter motor lead with a plastic locking
tie. Face the end of the plastic locking tie inward,
A. Fasten the left and right handlebar switch leads at and then cut off the excess end of the tie.
the positioning tape on each lead with a plastic
locking tie. Face the end of the plastic locking tie U. Route the horn 1 lead to the rear of the starter
inward, and then cut off the excess end of the tie. motor lead.
B. Fasten the left and right handlebar switch leads, V. Fasten the ignition coil lead at the white tape with
and cylinder-#2 left spark plug lead to the frame the holder.
with a plastic locking tie. Position the plastic locking W. Fasten the throttle cable (decelerator cable) at the
tie to the front of the projection on the frame. Face white paint mark with the holder.
the end of the plastic locking tie inward, and then X. Pass the plastic locking tie through the hole in the
cut off the excess end of the tie. rubber plate, and then fasten the wire harness with
C. Fasten the left and right handlebar switch leads to the tie.
the frame with a plastic locking tie. Face the end of Y. Fasten the stator coil lead at the white tape with a
the plastic locking tie inward, and then cut off the plastic locking tie.
Z. Fasten the stator coil lead with a plastic locking tie.
D. 30–40 mm (1.18–1.57 in)
AA.Pass the plastic locking tie through the hole in the
E. Fasten the left ignition coil lead and cylinder-#1 left battery box projection, and then fasten the wire
spark plug lead with plastic locking ties. Face the harness with the tie.
end of each plastic locking tie inward, and then cut
off the excess end of the tie. AB.Install the lead cover, making sure not to pinch the
stator coil lead and rectifier/regulator lead.
F. Fasten the crankshaft position sensor lead, neutral
switch lead and sidestand switch lead with the AC.Route the wire harness along the side of the fuse
holders. box/starter relay bracket.
G. Fasten the starter motor lead, speed sensor lead AD.Pass the plastic locking tie through the hole in the
and wire harness with the holders. battery box projection, and then fasten the wire
harness with the tie.
H. Route sub-wire harness 1 to the inside of the
frame. AE.For California only
I. To the tail/brake light AF. Route the horn 1 lead to the rear of the canister.
2-74
18 19
17
9 20 5
1
A-A
2
16
15
16
15 4 D D
14 I
A
H
B
13 C B
B
C 5 24 5
D 17
25
G E
C
B
23
F 21
A A 25 J
6 19
27
7 26
12 18 K
20
9 22
8
D-D C-C
11 B 10 9
R P L 9
30
S
T 6 M
Q 29
28
10 O N
2-75
1. Cylinder-#2 intake air pressure sensor coupler O. Route the positive battery lead (battery to starter
2. Meter assembly coupler relay) under the tray.
3. Fuel sender (fuel tank) coupler P. View with tray installed
4. Cylinder-#1 right spark plug cap Q. To the tail/brake light
5. Wire harness R. View with ECU removed
6. Negative battery lead S. Wrap the protective covering around the couplers
(crankshaft position sensor coupler, auxiliary DC
7. EXUP servo motor lead coupler, neutral switch coupler, sub-wire harness 1
8. Fuse box coupler, speed sensor coupler, sidestand switch
9. Starter motor lead coupler, and joint coupler).
10. Positive battery lead T. When installing the ECU, be sure not to pinch the
leads in the areas shown in the illustration with
11. Sub-wire harness 1 oblique lines.
13. Cylinder-#1 left spark plug cap
14. Cylinder-#1 intake air pressure sensor coupler
17. Neutral switch lead
18. Sidestand switch lead
19. Crankshaft position sensor lead
20. Speed sensor lead
21. Fuel hose (fuel tank to fuel hose joint)
25. Frame
26. Oil tank
27. Sub-fuel tank
28. Battery
29. Main fuse
30. Fuel pump lead
A. Align the white tape on the wire harness with the
frame cross member.
B. Fasten the wire harness with a plastic locking ties.
Face the end of the plastic locking tie upward, and
C. 20 mm (0.79 in)
D. Route the wire harness along the frame.
E. Fasten the wire harness with a plastic locking tie,
making sure to align the tie with the line on the
rubber damper. Face the end of the plastic locking
tie upward, and then cut off the excess end of the
tie.
F. Connect the ECU couplers, and then fasten the
ECU with the band.
G. Fasten the fuel return hose (fuel return pipe to sub-
fuel tank) to the frame with a plastic locking tie.
Face the end of the plastic locking tie inward, and
H. Route the cylinder-#1 intake air pressure sensor
lead so that it does not protrude past the top of the
frame.
I. Route the crankshaft position sensor lead,
sidestand switch lead, neutral switch lead, starter
motor lead and speed sensor lead under the fuel
outlet hose.
J. Inside of frame
K. Outside of frame
L. View with tray removed
M. Route the negative battery lead under the starter
motor lead and battery positive lead.
N. Route the positive battery lead (main fuse to
starter relay) over the tray.
2-76
1
2
3
4
E
5
6
A A
7
E 8
B B 11 D
C 9
12
10
11 15 F B F
13 A
A-A G
H H
14
12
13
C
C 3 7 K L 16
B-B I
S
14 J B
M
R
C-C 17
5
T V Q
U 4
P
O E
N
5 3
6
4
18
6
10
7
16
18
D
18
D
D-D F
19
2-77
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)
6. Fuel hose joint
7. Fuel outlet hose
8. Fuel pump
9. Sub-fuel tank
10. Fuel hose (fuel pump to fuel hose joint)
11. Fuel return pipe
14. Fuel tank breather/overflow pipe
17. Fuel pump coupler
19. Canister breather hose (for California only)
A. Install the fuel return hose (fuel return pipe to sub-
fuel tank) with its white paint mark facing upward.
B. Position the hose clamp over the white paint mark
on the hose, making sure not to install it on the
raised portion of the pipe.
C. Align the yellow paint mark on the air vent hose
(fuel hose joint to fuel tank) and fuel return hose
(fuel return pipe to sub-fuel tank) with the fuel hose
joint.
D. Face the fastener of the clamp downward, making
E. Align the white paint mark on the end of the fuel
return hose (fuel return pipe to sub-fuel tank) with
the white paint mark on the fuel return pipe.
F. Face the ends of the hose clamp outward.
G. Install the fuel return hose onto the fuel return pipe
until the hose contacts the white paint mark on the
pipe.
H. Align the ends of the hose clamps with the white
paint marks on the fuel return hose.
I. Face the ends of the hose clamp inward.
J. To the fuel injector
K. Align the clamp with the yellow paint mark, making
sure to face the fastener of the clamp to the left.
L. Face the ends of the hose clamp forward.
M. Install the air vent hose (fuel pump to fuel hose
joint) with its white paint mark facing upward.
N. Face the ends of the hose clamp upward.
O. Face the fastener of the clamp to the left.
P. Face the fastener of the clamp to the left. The
projections on the clamp may be facing in any
direction.
Q. Install the fuel hose (fuel tank to fuel hose joint)
R. To the pressure regulator
S. Install the air vent hose (fuel hose joint to fuel tank)
T. For California only
U. To the fuel tank
V. To the rollover valve
2-78
A
4 5
6
3 7 C
B 8 9
A C 10
2
1
FWD
G
B
15 D
11
12
F 14 11 E 9 13
9 H 16
11 C 11
9 9
C
I
B C-C
5
4
A
17
18
J
20 19
2-79

4. Fuel hose (intake manifold assembly to pressure
regulator)
hose
hose
16. Hose joint cover
17. Throttle position sensor coupler
18. Cylinder-#1 injector coupler
19. Engine temperature sensor coupler
A. Face the ends of the hose clamp to the left, angled
45° rearward.
B. Install the cylinder-#1 intake air pressure sensor
clamp forward.
C. Face the ends of the hose clamp to the left.
D. Face the ends of the hose clamp to the right.
E. Install the cylinder-#2 intake air pressure sensor
the pipe, making sure to face the yellow paint mark
clamp rearward.
F. Install the canister purge hose onto the throttle
body pipe up to the bend in the pipe, making sure
to face the yellow paint mark on the hose upward
(for California only).
G. Face the ends of the hose clamp rearward, angled
to the left.
H. Align the white paint marks.
I. Align the yellow paint marks.
J. Route the canister purge hose over the air filter
case joint clamp screw (for California only).
2-80
4
3 5
2 A
FWD
B C 8 A
9 7 6
C
14
13 8
F 7
10
11
12
B
8
J
H
6
J 6
7
8 G
B A
2-81

4. ISC (idle speed control) unit coupler
hose
hose
9. Hose joint
A. Face the ends of the hose clamp rearward.
B. Face the ends of the hose clamp outward.
C. Face the ends of the hose clamps outward.
D. Install the cylinder-#2 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold
assembly) completely onto the intake manifold,
making sure to face the pink paint mark on the
hose to the left. Face the ends of the hose clamp
outward, angled 45° forward.
E. To the canister (for California only)
F. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold
assembly) completely onto the intake manifold,
making sure to face the red paint mark on the hose
to the left.
G. Install the cylinder-#2 ISC (idle speed control) unit
align the green paint mark on the hose with the
green paint mark on the pipe.
H. Install the ISC (idle speed control) unit inlet hose
onto the ISC unit pipe, making sure to align the
white paint mark on the hose with the white paint
mark on the pipe.
I. Install the cylinder-#1 ISC (idle speed control) unit
align the blue paint mark on the hose with the blue
paint mark on the pipe.
J. 60°
2-82
2-83
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
ENGINE ...........................................................................................................3-4
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
SYNCHRONIZING THE THROTTLE BODIES.......................................... 3-7
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................3-8
CHECKING THE SPARK PLUGS ............................................................. 3-9
CHECKING THE IGNITION TIMING.......................................................3-10
CHECKING THE ENGINE OIL LEVEL....................................................3-11
CHANGING THE ENGINE OIL ...............................................................3-11
CHECKING THE TRANSFER GEAR OIL LEVEL................................... 3-13 3
CHANGING THE TRANSFER GEAR OIL............................................... 3-14
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-14
BLEEDING THE HYDRAULIC CLUTCH SYSTEM .................................3-15
REPLACING THE AIR FILTER ELEMENT ............................................. 3-15
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-16
CHECKING THE FUEL LINE .................................................................. 3-16
CHECKING THE CYLINDER HEAD BREATHER HOSE .......................3-17
CHECKING THE OIL TANK BREATHER HOSE .................................... 3-17
CHECKING THE EXHAUST SYSTEM (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C)) .................................................................. 3-17
CHECKING THE EXHAUST SYSTEM (for XV19CS(C)/ XV19C(C))...... 3-18
CHECKING THE CANISTER (for California only) (for XV19SC/
XV19MC/ XV19CTSC/ XV19CTMC) ......................................................3-19
CHECKING THE CANISTER
(for California only) (for XV19CSC/ XV19CC) ........................................ 3-19
ADJUSTING THE EXUP CABLES .......................................................... 3-19
CHASSIS ....................................................................................................... 3-21
ADJUSTING THE REAR DISC BRAKE .................................................. 3-21
CHECKING THE BRAKE FLUID LEVEL................................................. 3-21
CHECKING THE FRONT BRAKE PADS ................................................ 3-22
CHECKING THE REAR BRAKE PADS .................................................. 3-22
CHECKING THE FRONT BRAKE HOSES ............................................. 3-23
CHECKING THE REAR BRAKE HOSES................................................ 3-23
ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-23
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-24
ADJUSTING THE SHIFT PEDAL............................................................ 3-25
ADJUSTING THE DRIVE BELT SLACK ................................................. 3-26
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-27
CHECKING THE FRONT FORK ............................................................. 3-28
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-28
CHECKING THE TIRES..........................................................................3-29
CHECKING THE WHEELS ..................................................................... 3-31
CHECKING AND LUBRICATING THE CABLES .................................... 3-31
LUBRICATING THE LEVERS .................................................................3-32
LUBRICATING THE PEDALS .................................................................3-32
LUBRICATING THE SIDESTAND........................................................... 3-32
LUBRICATING THE REAR SUSPENSION............................................. 3-32
ELECTRICAL SYSTEM................................................................................. 3-33

CHECKING AND CHARGING THE BATTERY....................................... 3-33
CHECKING THE FUSES ........................................................................3-33
REPLACING THE HEADLIGHT BULBS (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C)) .................................................................. 3-33
REPLACING THE HEADLIGHT BULB (for XV19CS(C)/ XV19C(C))...... 3-34
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-35
PERIODIC MAINTENANCE
EAS20450
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 reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAU17600
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS
600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi

No. ITEM ROUTINE (13000 (19000 (25000 (31000
(1000 km) (7000 km) km) km) km) km)
or or
1 month 6 months or or or or
12 months 18 months 24 months 30 months
• Check fuel hoses for cracks or
1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition.
• Adjust gap and clean.
2 * Spark plugs • Replace every 8000 mi √ Replace. √ Replace. √
(13000 km) or 12 months.
• Check and adjust valve clear-
3 * Valve clearance ance when engine is cold. Every 16000 mi (25000 km)
• Adjust if necessary.
• Check breather hose for
4 * Crankcase cracks or damage. √ √ √ √ √
breather system
5 * Fuel injection • Adjust synchronization. √ √ √ √ √
• Check for leakage.
• Tighten if necessary.
6 * Exhaust system • Replace gasket(s) if neces- √ √ √ √ √
sary.
Evaporative emis-
sion control sys- • Check control system for
7 * damage. √ √
tem (for California • Replace if necessary.
only)
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the
service.
EAU32185
GENERAL MAINTENANCE AND LUBRICATION CHART

8000 mi 12000 mi 16000 mi 20000 mi
600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
• Check condition and for dam-
1 * Air filter element age. √ √ √ √ √
• Check operation and fluid
2 * Clutch leakage. √ √ √ √ √ √
• Correct if necessary.
• Check operation, fluid level,
3 * Front brake and for fluid leakage. √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check operation, fluid level,
and for fluid leakage.
4 * Rear brake • Replace brake pads if neces- √ √ √ √ √ √
sary.
• Check for cracks or damage. √ √ √ √ √
5 * Brake hoses
• Replace. Every 4 years
3-1

8000 mi 12000 mi 16000 mi 20000 mi
600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
• Check runout and for dam-
6 * Wheels age. √ √ √ √ √
• Check tread depth and for
damage.
7 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Check bearings for smooth
8 * Wheel bearings operation. √ √ √ √ √
Swingarm pivot • Check bearing assemblies for
9 * bearings looseness. √ √ √ √ √
10 * Drive belt • Check belt tension. √ Every 2500 mi (4000 km)

• Adjust if necessary.
• Check bearing assemblies for
looseness.
• Moderately repack with lithi-
11 * Steering bearings um-soap-based grease every √ √ √ √ Repack. √
16000 mi (25000 km) or 24
months.
• Check all chassis fitting and
12 * Chassis fasteners fasteners. √ √ √ √ √
Brake lever pivot
13 • Apply silicone grease lightly. √ √ √ √ √
shaft
• Apply lithium-soap-based
14 Brake pedal pivot grease (all-purpose grease) √ √ √ √ √
shaft
lightly.
Clutch lever pivot
15 shaft • Apply silicone grease lightly. √ √ √ √ √
Shift pedal pivot • Apply lithium-soap-based

16 grease (all-purpose grease) √ √ √ √ √
shaft
lightly.
• Check operation.
• Apply lithium-soap-based
17 Sidestand pivot √ √ √ √ √
grease (all-purpose grease)
lightly.
• Check operation and replace
18 * Sidestand switch √ √ √ √ √ √
if necessary.
• Check operation and for oil
19 * Front fork leakage. √ √ √ √ √
• Check operation and for oil
20 * Shock absorber leakage. √ √ √ √ √
assembly
Rear suspension • Apply lithium-soap-based
21 * link pivots grease lightly. √
22 Engine oil • Change (warm engine before √ √ √ √ √ √

draining).
Engine oil filter
23 * • Replace. √ √ √
cartridge
• Check for leakage.
• Change at initial 600 mi (1000
24 * Transfer case oil km) or 1 month, and thereaf- Change. √ Change.
ter every 16000 mi (25000
km) or 24 months.
25 * Front and rear • Check operation. √ √ √ √ √ √
brake switches
• Apply Yamaha chain and ca-
26 * Control cables ble lube or engine oil SAE √ √ √ √ √ √
10W-30 thoroughly.
• Check operation and free
Throttle grip play.
• Adjust the throttle cable free
27 * housing and ca- play if necessary. √ √ √ √ √
ble
• Lubricate the throttle grip
housing and cable.
Lights, signals • Check operation.
28 * √ √ √ √ √ √
and switches • Adjust headlight beam.
3-2
* 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 model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• Hydraulic brake and clutch systems
• After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder,
always change the fluid. Regularly check the brake and clutch fluid levels and fill the reservoirs as
required.
• Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and
clutch release cylinder every two years.
• Replace the brake and clutch hoses every four years or if cracked or damaged.
3-3
ENGINE
EAS20470
• Fuel tank
ENGINE Refer to “FUEL TANK” on page 6-1.
EAS20530
• Air filter case
ADJUSTING THE VALVE CLEARANCE Refer to “GENERAL CHASSIS” on page 4-1.
The following procedure applies to all of the • Muffler
valves. • Exhaust pipes
NOTE: Refer to “ENGINE REMOVAL” on page 5-1.
2. Disconnect:
• The valve clearance is automatically adjusted
• Spark plug caps
by the hydraulic valve lifter. However, there are
3. Remove:
times when the valve clearance needs to be
• Spark plugs
adjusted manually. If this is the case, adjust the
4. Remove: (for XV19S(C)/ XV19M(C)/
clearance of the two maladjusted or worn
valves using the adjusting screw on the rocker
• Shift pedal assembly “1”
arm.
If clearance is on the slip side “1”, loosen the
adjusting screw and bring the valve clearance
“a” within specification. Check if the valve
clearance “b” on the adjusting screw “2” side is
within specification.
5. Remove:
• Damper cover “1”
• Damper “2”
• Timing mark accessing screw “3”
• Crankshaft end screw “4”
If clearance is on the adjusting screw “2” side,
tighten the adjusting screw and bring the valve 4
clearance “b” within specification.
3 2
1
6. Remove:
• Camshaft sprocket cover “1”
• Valve clearance adjustment should be made

on a cold engine, at room temperature.
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center 1
(TDC) on the compression stroke.
1. Remove:
• Rider seat
• Rider seat bracket assembly
Refer to “GENERAL CHASSIS” on page 4-1. 7. Remove:
• Wire harness guide bolt “1”
3-4
ENGINE
1 3
2
3
8. Remove: 11.Measure:
• Fuel tank damper “1” • Valve clearance
• Cylinder head breather hose “2” Out of specification → Adjust.
9. Disconnect:
• Oil tank breather hose “3” Valve clearance (cold)
• Fuel outlet hose “4” Intake
0.00–0.04 mm (0.0000–0.0016 in)
1 Exhaust
0.00–0.04 mm (0.0000–0.0016 in)
3
4 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Piston #1 TDC (rear cylinder)
2
a. Turn the crankshaft counterclockwise.
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 cover, the three bolts
“3” cannot be removed when the cover is in
b. When piston #1 is at TDC on the compres-
place. Loosen the bolts, and then remove the
sion stroke, align the TDC mark “a” on the
cylinder head cover from the right side of the ve-
crankshaft position sensor rotor with the
hicle, making sure that the bolts do not scratch
pointer “b” on the clutch cover.
the rocker arms or other engine parts.
b a
1
c. Check the camshaft drive gear mark “c” posi-

tion and camshaft driven gear mark “d” posi-
tion as shown.
If the marks are not aligned, turn the crank-
shaft counterclockwise 360 degrees and re-
check step (b).
3-5
ENGINE
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
d
c ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
12.Adjust:
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
d. Measure the valve clearance with a thickness
gauge.
Thickness gauge
90890-03180 1
Feeler gauge set
YU-26900-9
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Piston #2 TDC (front cylinder)
b. Insert a thickness gauge “2” between the end
a. Turn the crankshaft counterclockwise from
of the adjusting screw and the valve tip.
the piston #1 TDC by 408 degrees.
b. When piston #2 is at TDC on the compres- Thickness gauge
sion stroke, align the TDC mark “e” on the 90890-03180
crankshaft position sensor rotor with the Feeler gauge set
pointer “b” on the clutch cover. YU-26900-9
b e c. Turn the adjusting screw “3” in direction “a” or

“b” with the tappet adjusting tool “4” until the
specified valve clearance is obtained.
Tappet adjusting tool (4 mm)

90890-04133
Six piece tappet set
YM-A5970
c. Check the camshaft drive gear mark “c” posi- Adjusting

Slip side
screw side
tion and camshaft driven gear mark “d” posi-
tion as shown. Valve clear- Valve clear-
Direction “a” ance is in- ance is de-
d creased. creased.
Valve clear- Valve clear-
Direction “b” ance is de- ance is in-
creased. creased.
c
d. Measure the valve clearance with a thickness

gauge.
3-6
ENGINE
• Fuel tank
Refer to “FUEL TANK” on page 6-1.
3 2 3. Remove:
4
• Cylinder-#1 intake air pressure sensor brack-
et “1”
• Cylinder-#2 intake air pressure sensor brack-
b et “2”
a
2
d. Hold the adjusting screw to prevent it from

moving and tighten the locknut to specifica- 1
tion.
Locknut (rocker arm adjusting

screw)
T.
R.
20 Nm (2.0 m·kg, 14 ft·lb)

4. Disconnect:
Tappet adjusting tool (4 mm) • Cylinder-#1 intake air pressure sensor hose
90890-04133 “1”
Six piece tappet set • Cylinder-#2 intake air pressure sensor hose
YM-A5970 “2”
e. Measure the valve clearance again.

f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust- 2
ment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
13.Install:
• All removed parts
Refer to “CAMSHAFTS” on page 5-17.
NOTE: 5. Install:
For installation, reverse the removal procedure. • Hose “1” (Parts No.: 5JW-24311-00)
• 3-way joint “2” (Parts No.: 90413-05014)
EAS20570
• Vacuum gauge hose for #1 “3”
SYNCHRONIZING THE THROTTLE BODIES • Vacuum gauge hose for #2 “4”
NOTE: • Cylinder-#1 intake air pressure sensor hose
Prior to synchronizing the throttle bodies, the “5”
valve clearance and the engine idling speed • Cylinder-#2 intake air pressure sensor hose
should be properly adjusted and the ignition tim- “6”
ing should be checked. • Vacuum gauge
• Tachometer
1. Stand the vehicle on a level surface.
NOTE: Vacuum gauge
90890-03094
Place the vehicle on a suitable stand.
Carburetor synchronizer
2. Remove: YU-44456
• Rider seat
Refer to “GENERAL CHASSIS” on page 4-1.
• Cylinder-#1 ignition coil cover
Refer to “ENGINE REMOVAL” on page 5-1.
3-7
ENGINE
NOTE:
4 The difference in vacuum pressure between two
throttle bodies should not exceed 1.33 kPa (10
6 mmHg).
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 1 8. Stop the engine and remove the measuring
equipment.
5
3 9. Adjust:
2
• Throttle cable free play
6. Install: Refer to “ADJUSTING THE THROTTLE CA-
• Fuel tank BLE FREE PLAY” on page 3-8.
7. Adjust: Throttle cable free play
• Throttle body synchronization 4.0–6.0 mm (0.16–0.24 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine and let it warm up for several 10.Install:
minutes, and then let it run at specified en- • Fuel tank
gine idling speed. Refer to “FUEL TANK” on page 6-1.
• Cylinder-#1 ignition coil cover
Engine idling speed Refer to “ENGINE REMOVAL” on page 5-1.
850–950 r/min • Rider seat bracket assembly
• Rider seat
b. With throttle body #1 as standard, adjust Refer to “GENERAL CHASSIS” on page 4-1.
throttle body #2 using the air screw “1” (for
EAS20630
throttle body #2).
ADJUSTING THE THROTTLE CABLE FREE
1 PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed and throttle body synchroni-
zation should be adjusted properly.
1. Check:
• Throttle cable free play “a”
Out of specification → Adjust.
NOTE:
• After each step, rev the engine two or three
times, each time for less than a second, and
check the synchronization again.
• If the air screw was removed, turn the screw
3/4 turn in and be sure to synchronize the throt- a
tle body.
ECA14900
CAUTION:
Do not use the throttle valve adjusting Throttle cable free play
screws to adjust the throttle body synchroni- 4.0–6.0 mm (0.16–0.24 in)
zation.
2. Adjust:
Intake vacuum • Throttle cable free play
31.3–35.3 kPa (9.2–10.4 inHg) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(235–265 mmHg) a. Loosen the locknut “1”.
3-8
ENGINE
b. Turn the adjusting nut “2” in direction “a” or “b”

until the specified throttle cable free play is Manufacturer/model
obtained. NGK/DPR8EA-9
Manufacturer/model
Direction “a” DENSO/X24EPR-U9
Throttle cable free play is increased.
Direction “b” 5. Check:
Throttle cable free play is decreased. • Electrode “1”
Damage/wear → Replace the spark plug.
c. Tighten the locknut “1”. • Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• Spark plug
(with a spark plug cleaner or wire brush)
2
a 7. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
1 b Out of specification → Regap.
EWA12910
Spark plug gap
WARNING 0.8–0.9 mm (0.031–0.035 in)
After adjusting the throttle cable free play,
start the engine and turn the handlebar to the
right and to the left to ensure that this does
not cause the engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20680
CHECKING THE SPARK PLUGS

The following procedure applies to all of the
spark plugs.
1. Remove:
• Rider seat 8. Install:
• Rider seat bracket assembly • Spark plug
• Fuel tank Spark plug
18 Nm (1.8 m·kg, 13 ft·lb)
T.

R.
• Air filter case

NOTE:
2. Disconnect: Before installing the spark plug, clean the spark
• Spark plug cap plug and gasket surface.
3. Remove: 9. Connect:
• Spark plug • Spark plug cap
ECA13320
10.Install:
CAUTION:
• Air filter case
Before removing the spark plugs, blow away Refer to “GENERAL CHASSIS” on page 4-1.
any dirt accumulated in the spark plug wells • Fuel tank
with compressed air to prevent it from falling Refer to “FUEL TANK” on page 6-1.
into the cylinders. • Rider seat bracket assembly
4. Check: • Rider seat
• Spark plug type Refer to “GENERAL CHASSIS” on page 4-1.
Incorrect → Change.
3-9
ENGINE
EAS20700
CHECKING THE IGNITION TIMING

NOTE:
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure all connections are tight and free of
corrosion.
1. Stand the vehicle on a level surface. 1
• Shift pedal assembly “1” 5. Check:
• Ignition timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
Engine idling speed

1 850–950 r/min
b. Check that pointer “a” on the clutch cover is

within the firing range “b” on the crankshaft
3. Remove: position sensor rotor.
• Damper cover “1” Incorrect firing range → Check the ignition
• Damper “2” system.
• Timing mark accessing screw “3”
a b
3 2
1
NOTE:
4. Connect: The ignition timing is not adjustable.
• Timing light “1”
• Tachometer ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
Timing light • Timing mark accessing screw
90890-03141 • Damper
Inductive clamp timing light • Damper cover
YU-03141
Damper cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
7. Install: (for XV19S(C)/ XV19M(C)/

Shift pedal bolt

18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
3-10
ENGINE
NOTE:
Type
Align the mark “a” on the shift pedal shaft with YAMALUBE 4 (20W40) or
the slot in the shift pedal. SAE20W40
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
1 ECA13380
CAUTION:
• Engine oil also lubricates the clutch and the
wrong oil types or additives could cause
clutch slippage. Therefore, do not add any
a
chemical additives.
• Do not allow foreign materials to enter the
EAS20750 crankcase.
CHECKING THE ENGINE OIL LEVEL
1. Stand the vehicle on a level surface. 6. Start the engine, warm it up for several min-
utes, and then turn it off.
NOTE:
7. Check the engine oil level again.
• Place the vehicle on a suitable stand.
NOTE:
• Make sure the vehicle is upright.
Before checking the engine oil level, wait a few
2. Start the engine, warm it up for approximately minutes until the oil has settled.
15 minutes until the oil temperature rises to
60 °C (140 °F), and then turn it off. 8. Install:
3. Remove: • Dipstick
• Rider seat 9. Install:
Refer to “GENERAL CHASSIS” on page 4-1. • Rider seat
4. Remove: Refer to “GENERAL CHASSIS” on page 4-1.
• Dipstick “1” EAS20780
5. Check: CHANGING THE ENGINE OIL

• Engine oil level 1. Start the engine, warm it up for several min-
The engine oil level should be between the utes, and then turn it off.
minimum level mark “a” and maximum level 2. Place a container under the engine oil drain
mark “b”. bolts.
Below the minimum level mark → Add the 3. Remove:
recommended engine oil to the proper level. • Engine oil filler cap “1”
NOTE:
1
• Before checking the engine oil level, wait a few
minutes until the oil has settled.
• Do not screw the dipstick in when inspecting
the oil level.
a
1
4. Remove:
• Engine oil drain bolt (oil tank) “1”
(along with the gasket)
3-11
ENGINE
5. Remove: c. Tighten the new oil filter cartridge to specifi-

• Engine oil drain bolts (crankcase) “1” cation with an oil filter wrench.
(along with the gaskets)
Oil filter cartridge
17 Nm (1.7 m·kg, 12 ft·lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Check:
• Engine oil drain bolt gaskets
Damage → Replace.
9. Install:
• Engine oil drain bolt (oil tank)
1 1 (along with the gasket)
6. Drain: Engine oil drain bolt (oil tank)
• Engine oil 43 Nm (4.3 m·kg, 31 ft·lb)
T.
R.
(completely from the oil tank and crankcase)

7. If the oil filter cartridge is also to be replaced, 10.Install:
perform the following procedure. • Engine oil drain bolts (crankcase)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ (along with the gaskets)
a. Remove the oil filter cartridge “1” with an oil
filter wrench “2”. Engine oil drain bolt (crankcase)
43 Nm (4.3 m·kg, 31 ft·lb)
T.
R.
Oil filter wrench

90890-01426 11.Fill:
YU-38411 • Oil tank
(with the specified amount of the recom-
mended engine oil)
Engine oil quantity

Total amount
5.20 L (5.50 US qt) (4.58 Imp.qt)
Without oil filter cartridge re-
placement
4.10 L (4.33 US qt) (3.61 Imp.qt)
With oil filter cartridge replace-
ment
4.90 L (5.18 US qt) (4.31 Imp.qt)
b. Lubricate the O-ring “3” of the new oil filter
cartridge with a thin coat of engine oil.
ECA13390 NOTE:
CAUTION: Pour the engine oil in two stages. First, pour in
Make sure the O-ring “3” is positioned cor- 2.5 L of oil, then start the engine and rev it 3 to 5
rectly in the groove of the oil filter cartridge. times. Stop the engine, and then pour in the re-
mainder of the specified amount.
3-12
ENGINE
EC1D71008
CAUTION: Oil gallery bolt

When starting the engine make sure the dip- XV19S(C)/ XV19M(C)/
T.
R.
stick is securely fitted into the oil tank. XV19CTS(C)/ XV19CTM(C):
10 Nm (1.0 m·kg, 7.2 ft·lb)
12.Fill: (when engine is disassembled) XV19CS(C)/ XV19C(C):
• Crankcase and oil tank 8 Nm (0.8 m·kg, 5.8 ft·lb)
mended engine oil) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20840
Engine oil quantity CHECKING THE TRANSFER GEAR OIL
Total amount LEVEL
5.20 L (5.50 US qt) (4.58 Imp.qt) 1. Stand the vehicle on a level surface.
Engine
3.2 L (3.38 US qt) (2.82 Imp.qt) NOTE:
Oil tank • Place the vehicle on a suitable stand.
2.0 L (2.11 US qt) (1.76 Imp.qt) • Make sure the vehicle is upright.
13.Install: 2. Remove:
• Engine oil filler cap • Transfer gear oil check bolt “1”
14.Start the engine, warm it up for several min-
utes, and then turn it off.
15.Check:
• Engine
(for engine oil leaks)
16.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
1
LEVEL” on page 3-11.
17.Check:
• Engine oil pressure 3. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Transfer gear oil level
a. Slightly loosen the oil gallery bolts “1”. The transfer gear oil level should be up to the
brim “1” of the hole.
Below the brim → Add the recommended
transfer gear oil to the proper level.
1 1
b. Start the engine and keep it idling until engine

oil starts to seep from the oil gallery bolts. If
no engine oil comes out after one minute, turn
the engine off so that it will not seize.
c. Check the engine oil passages, the oil filter Type
cartridge and the oil pump for damage or SAE80 API GL-4 Hypoid gear oil
leakage. Refer to “OIL PUMP” on page EC1D71024
5-100. CAUTION:
d. Start the engine after solving the problem(s) Do not allow foreign materials to enter the
and check the engine oil pressure again. transfer gear case.
e. Tighten the oil gallery bolts to specification.
3-13
ENGINE
4. Install:
• Transfer gear oil check bolt
Transfer gear oil check bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
R.
EAS20850
CHANGING THE TRANSFER GEAR OIL

1. Remove:
• Muffler
• Exhaust pipes
Refer to “ENGINE REMOVAL” on page 5-1. 8. Install:
2. Place a container under the transfer gear oil • Straight plug
drain bolt. 9. Check:
3. Remove: • Transfer gear oil level
• Straight plug “1” Refer to “CHECKING THE TRANSFER
• Transfer gear oil drain bolt “2” GEAR OIL LEVEL” on page 3-13.
10.Install:
• Exhaust pipes
• Muffler
EAS20890
CHECKING THE CLUTCH FLUID LEVEL

NOTE:
2
1 Place the vehicle on a suitable stand.
4. Drain: 2. Check:
• Transfer gear oil • Clutch fluid level
(completely from the transfer gear case) Below the minimum level mark “a” → Add the
5. Check: recommended clutch fluid to the proper level.
• Transfer gear oil drain bolt gasket
Recommended clutch fluid
Damage → Replace. Brake fluid DOT 4
6. Install:
• Transfer gear oil drain bolt
(along with the gasket)
Transfer gear oil drain bolt

18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
7. Fill:
• Transfer gear case
mended transfer gear oil)
EWA13370
Quantity
0.55 L (0.58 US qt) (0.48 Imp.qt) WARNING
Quantity (disassembled) • Use only the designated clutch fluid. Other
0.60 L (0.63 US qt) (0.53 Imp.qt) 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 chemical reac-
tion, leading to poor clutch performance.
3-14
ENGINE
• When refilling, be careful that water does

not enter the clutch fluid reservoir. Water 1
will significantly lower the boiling point of 2
the clutch fluid and could cause vapor lock.
ECA13420
CAUTION:
Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.
NOTE: d. Place the other end of the hose into a con-
In order to ensure a correct reading of the clutch tainer.
fluid level, make sure the top of the reservoir is e. Slowly squeeze the clutch lever several
horizontal. times.
f. Fully squeeze the clutch lever without releas-
EAS20900 ing it.
BLEEDING THE HYDRAULIC CLUTCH g. Loosen the bleed screw. This will release the
SYSTEM tension and cause the clutch lever to contact
EWA13000
WARNING the handlebar grip.

h. Tighten the bleed screw and then release the
Bleed the hydraulic clutch system whenever:
clutch lever.
• the system was disassembled,
i. Repeat steps (e) to (h) until all of the air bub-
• a clutch hose was loosened or removed,
bles have disappeared from the clutch fluid in
• the clutch fluid level is very low,
the plastic hose.
• clutch operation is faulty.
j. Tighten the bleed screw to specification.
NOTE:
Bleed screw (clutch release cylin-
• Be careful not to spill any clutch fluid or allow der)
T.
the clutch master cylinder reservoir to over-

R.
6 Nm (0.6 m·kg, 4.3 ft·lb)

flow.
• When bleeding the hydraulic clutch system, k. Add the recommended clutch fluid to the
make sure there is always enough clutch fluid proper level.
before applying the clutch lever. Ignoring this Refer to “CHECKING THE CLUTCH FLUID
precaution could allow air to enter the hydraulic LEVEL” on page 3-14.
clutch system, considerably lengthening the EWA13010
bleeding procedure. WARNING

• If bleeding is difficult, it may be necessary to let After bleeding the hydraulic clutch system,
the clutch fluid settle for a few hours. Repeat check the clutch operation.
the bleeding procedure when the tiny bubbles
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
in the hose have disappeared.
EAS20960
1. Bleed: REPLACING THE AIR FILTER ELEMENT

• Hydraulic clutch system 1. Remove:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rider seat
a. Add the recommended clutch fluid to the Refer to “GENERAL CHASSIS” on page 4-1.
proper level. 2. Remove:
b. Install the clutch master cylinder reservoir di- • Fuel tank
aphragm. Refer to “FUEL TANK” on page 6-1.
c. Connect a clear plastic hose “1” tightly to the 3. Remove:
bleed screw “2”. • Air filter case cover “1”
3-15
ENGINE
EAS21010
CHECKING THE THROTTLE BODY JOINTS

1 throttle body joints and intake manifolds.
1. Remove:
• Rider seat
• Fuel tank
• Air filter case
4. Remove:
• Air filter element “1”
2. Check:
• Throttle body joints “1”
1 Cracks/damage → Replace.
5. Check:
• Air filter element
Damage → Replace.
3. Install:
NOTE: • Air filter case
The air filter needs more frequent service if you Refer to “GENERAL CHASSIS” on page 4-1.
are riding in unusually wet or dusty areas. • Fuel tank
6. Install: Refer to “FUEL TANK” on page 6-1.
• Air filter case cover • Rider seat bracket assembly
EC1D71002 • Rider seat
CAUTION: Refer to “GENERAL CHASSIS” on page 4-1.
Never operate the engine without the air filter EAS21030
element installed. Unfiltered air will cause CHECKING THE FUEL LINE
rapid wear of engine parts and may damage The following procedure applies to all of the fuel,
the engine. Operating the engine without the air vent and breather hoses.
air filter element will also affect the throttle 1. Remove:
body synchronization, leading to poor en- • Rider seat
gine performance and possible overheating. • Rider seat bracket assembly
NOTE:
• Fuel tank
When installing the air filter element into the air Refer to “FUEL TANK” on page 6-1.
filter case, make sure that the sealing surfaces 2. Check:
are aligned to prevent any air leaks. • Fuel hoses “1”
7. Install: • Air vent hose “2”
• Fuel tank • Breather hose “3”
Refer to “FUEL TANK” on page 6-1. Cracks/damage → Replace.
• Rider seat Loose connection → Connect properly.
ECA14940
CAUTION:
Make sure the fuel tank breather hose is rout-
ed correctly.
3-16
ENGINE
2
1 1
3. Install:
3 • Air filter case
• Fuel tank
1
• Rider seat
EAS21060
CHECKING THE OIL TANK BREATHER

3. Install: HOSE
• Fuel tank 1. Remove:
Refer to “FUEL TANK” on page 6-1. • Right side cover
• Rider seat bracket assembly Refer to “GENERAL CHASSIS” on page 4-1.
• Rider seat 2. Check:
Refer to “GENERAL CHASSIS” on page 4-1. • Oil tank breather hose “1”
Cracks/damage → Replace.
EAS21050
CHECKING THE CYLINDER HEAD ECA14930
BREATHER HOSE CAUTION:

1. Remove: Make sure the oil tank breather hose is rout-
• Rider seat ed correctly.
1
• Fuel tank
• Air filter case
2. Check:
• Cylinder head breather hose “1”
ECA14920
CAUTION: 3. Install:
Make sure the cylinder head breather hose is • Right side cover
routed correctly. Refer to “GENERAL CHASSIS” on page 4-1.
EAS21080
CHECKING THE EXHAUST SYSTEM (for

XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C))
The following procedure applies to all of the ex-
haust pipes and gaskets.
3-17
ENGINE
1. Check: EAS1D77002
CHECKING THE EXHAUST SYSTEM (for

• Front exhaust pipe “1”
XV19CS(C)/ XV19C(C))
• Rear exhaust pipe “2”
The following procedure applies to all of the ex-
• Muffler “3”
haust pipes and gaskets.
• Muffler bracket “4”
1. Check:
• Front exhaust pipe “1”
• Gaskets “5”
• Rear exhaust pipe “2”
Exhaust gas leaks → Replace.
• Muffler “3”
2. Check:
• Muffler bracket “4”
Tightening torque
• Front exhaust pipe nuts “6”
• Gaskets “5”
• Front exhaust pipe and rear exhaust pipe bolt
Exhaust gas leaks → Replace.
“7”
2. Check:
• Rear exhaust pipe nuts “8”
Tightening torque
• Rear exhaust pipe and muffler bolt “9”
• Front exhaust pipe nuts “6”
• Muffler and muffler bracket bolts “10”
• Front exhaust pipe and rear exhaust pipe bolt
• Muffler bracket and frame bolts “11”
“7”
Front exhaust pipe nut • Rear exhaust pipe nuts “8”
20 Nm (2.0 m·kg, 14 ft·lb) • Rear exhaust pipe and muffler bolt “9”
T.
R.
Front exhaust pipe and rear ex- • Muffler and muffler bracket bolts “10”
haust pipe bolt • Muffler bracket and frame bolts “11”
20 Nm (2.0 m·kg, 14 ft·lb) • Muffler and frame bolt “12”
Rear exhaust pipe nut
24 Nm (2.4 m·kg, 17 ft·lb) Front exhaust pipe nut
Rear exhaust pipe and muffler 20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
bolt Front exhaust pipe and rear ex-

20 Nm (2.0 m·kg, 14 ft·lb) haust pipe bolt
Muffler and muffler bracket bolt 20 Nm (2.0 m·kg, 14 ft·lb)
29 Nm (2.9 m·kg, 21 ft·lb) Rear exhaust pipe nut
Muffler bracket and frame bolt 24 Nm (2.4 m·kg, 17 ft·lb)
53 Nm (5.3 m·kg, 38 ft·lb) Rear exhaust pipe and muffler
LOCTITE® bolt
20 Nm (2.0 m·kg, 14 ft·lb)
Muffler and muffler bracket bolt
29 Nm (2.9 m·kg, 21 ft·lb)
Muffler bracket and frame bolt
53 Nm (5.3 m·kg, 38 ft·lb)
LOCTITE®
Muffler and frame bolt
3 10 20 Nm (2.0 m·kg, 14 ft·lb)
4
LT
LT
11
9 8
5 5
5
2
7
5
6
1
3-18
ENGINE
2. Check:
• Canister “1”
• Canister hose “2”
12 • Canister purge hose
4
• Canister breather hose “3”
10 • Fuel tank breather/overflow pipe “4”
3
11
LT
5
9 2
8 2
4
5 1 2
5
3
6
7 1 3. Install:
5 • Horn 1
6
Refer to “THROTTLE BODIES” on page 6-7.
EAS21090 EAS21100
CHECKING THE CANISTER (for California ADJUSTING THE EXUP CABLES

only) (for XV19SC/ XV19MC/ XV19CTSC/ 1. Remove:
XV19CTMC) • EXUP valve pulley cover “1”
1. Remove:
• Horn 1
2. Check:
• Canister “1”
• Canister purge hose “2”
• Canister breather hose “3”
• Fuel tank breather/overflow hose “4” 1
2. Check:
• EXUP system operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the main switch to “ON”.
2 4 b. Check that the EXUP valve operates proper-
ly.
1 NOTE:
Check that the projection “a” on the EXUP valve
3 pulley contact the stopper “b” (fully-open posi-
3. Install: tion) and the stopper “c” (fully-closed position).
• Horn 1
EAS1D77007
CHECKING THE CANISTER (for California

only) (for XV19CSC/ XV19CC)
1. Remove:
• Horn 1
3-19
ENGINE
b b 2
a
b
a a
c 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ c. Tighten both locknuts.

3. Check: d. Turn the main switch to “ON” and check that
• EXUP cable free play (at the EXUP valve pul- the projection “c” on the EXUP valve pulley
ley) “a” and “b” contacts the stoppers (fully open and fully
closed positions), then stops between the
EXUP cable free play (at the lines “d” on the cable holder.
EXUP valve pulley)
a: 3 mm (0.12 in) or less
b: 3 mm (0.12 in) or less
b
d
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• EXUP valve pulley cover
4. Adjust: EXUP valve pulley cover bolt
• EXUP cable free play 7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts “1”.
b. Turn both adjusting bolts “2” in or out until the

specification.
Turn in “a” →
Free play is increased.
Turn out “b” →
Free play is decreased.
3-20
CHASSIS
EAS21140 EWA13070
CHASSIS WARNING
After adjusting the brake pedal position,
EAS21190
ADJUSTING THE REAR DISC BRAKE check that the end of the adjusting bolt “c” is
1. Check: visible through the hole “d”.
• Brake pedal position
(distance “a” from the top of the rider footrest
to the top of the brake pedal)
1
Out of specification → Adjust. a
Brake pedal position

XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C): b
110.0 mm (4.33 in)
XV19CS(C)/ XV19C(C): 2
93.0 mm (3.66 in)
A 2 1 c
c. Tighten the locknut.

B EW1D71005
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
a system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance.
ECA13510
CAUTION:
A. For XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C) After adjusting the brake pedal position,
B. For XV19CS(C)/ XV19C(C) make sure there is no brake drag.
2. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Brake pedal position 3. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rear brake light switch
a. Loosen the locknut “1”. Refer to “ADJUSTING THE REAR BRAKE
b. Turn the adjusting bolt “2” in direction “a” or LIGHT SWITCH” on page 3-23.
“b” until the specified brake pedal position is
EAS21240
obtained.
CHECKING THE BRAKE FLUID LEVEL
Direction “a” 1. Stand the vehicle on a level surface.
Brake pedal is raised. NOTE:
Direction “b” • Place the vehicle on a suitable stand.
Brake pedal is lowered. • Make sure the vehicle is upright.
3-21
CHASSIS
2. Remove: ECA13540
• Rider seat CAUTION:

Refer to “GENERAL CHASSIS” on page 4-1. Brake fluid may damage painted surfaces
3. Check: and plastic parts. Therefore, always clean up
• Brake fluid level any spilt brake fluid immediately.
Below the minimum level mark “a” → Add the
NOTE:
recommended brake fluid to the proper level.
In order to ensure a correct reading of the brake
Front brake fluid level, make sure the top of the brake fluid
Recommended fluid reservoir is horizontal.
DOT 4
4. Install:
Rear brake
Recommended fluid • Rider seat
DOT 4 Refer to “GENERAL CHASSIS” on page 4-1.
EAS21250
CHECKING THE FRONT BRAKE PADS

brake pads.
1. Operate the brake.
2. Check:
• Front brake pad
Wear indicator grooves “1” almost disap-
peared → Replace the brake pads as a set.
Refer to “FRONT BRAKE” on page 4-35.
1
a
EAS21260
A. Front brake CHECKING THE REAR BRAKE PADS

B. Rear brake The following procedure applies to all of the
brake pads.
EWA13090
1. Operate the brake.
WARNING
2. Check:
• Use only the designated brake fluid. Other • Rear brake pad
brake fluids may cause the rubber seals to Wear indicators “1” almost touch the brake
deteriorate, causing leakage and poor disc → Replace the brake pads as a set.
brake performance. Refer to “REAR BRAKE” on page 4-47.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
leading to poor brake performance.
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.
3-22
CHASSIS
1
1
1
1
3. Check:
EAS21280
CHECKING THE FRONT BRAKE HOSES • Brake hose clamp

The following procedure applies to all of the Loose connection → Tighten the clamp bolt.
brake hoses and brake hose clamps. 4. Check:
1. Check: • Brake hose guide
• Brake hoses “1” Loose → Tighten the guide bolt.
Cracks/damage/wear → Replace. 5. Hold the vehicle upright and apply the brake
several times.
1 6. Check:
• Brake hoses
Brake fluid leakage → Replace the damaged
hose.
1 Refer to “REAR BRAKE” on page 4-47.
EAS21330
ADJUSTING THE REAR BRAKE LIGHT

SWITCH
NOTE:
2. Check: The rear brake light switch is operated by move-
• Brake hose clamps ment of the brake pedal. The rear brake light
Loose → Tighten the clamp bolt. switch is properly adjusted when the brake light
3. Hold the vehicle upright and apply the brake comes on just before the braking effect starts.
several times.
4. Check: 1. Check:
• Brake hoses • Rear brake light operation timing
Brake fluid leakage → Replace the damaged Incorrect → Adjust.
hose. 2. Adjust:
Refer to “FRONT BRAKE” on page 4-35. • Rear brake light operation timing
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS21290 a. Hold the main body “1” of the rear brake light
CHECKING THE REAR BRAKE HOSES switch so that it does not rotate and turn the
1. Remove: adjusting nut “2” in direction “a” or “b” until the
• Rider seat rear brake light comes on at the proper time.
2. Check: Direction “a”
• Brake hoses “1” Brake light comes on sooner.
Cracks/damage/wear → Replace. Direction “b”
Brake light comes on later.
3-23
CHASSIS
1 2
2
a
b
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
B
EAS21350
BLEEDING THE HYDRAULIC BRAKE

SYSTEM
EWA13100
WARNING 2
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or 1
replaced.
• the brake fluid level is very low.
A. Front
• brake operation is faulty.
B. Rear
1. Remove:
• Rider seat d. Place the other end of the hose into a con-
Refer to “GENERAL CHASSIS” on page 4-1. tainer.
e. Slowly apply the brake several times.
NOTE:
f. Fully pull the brake lever or fully press down
• Be careful not to spill any brake fluid or allow the brake pedal and hold it in position.
the brake master cylinder reservoir or brake g. Loosen the bleed screw.
fluid reservoir to overflow.
NOTE:
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid Loosening the bleed screw will release the pres-
before applying the brake. Ignoring this pre- sure and cause the brake lever to contact the
caution could allow air to enter the hydraulic throttle grip or the brake pedal to fully extend.
brake system, considerably lengthening the h. Tighten the bleed screw and then release the
bleeding procedure. brake lever or brake pedal.
• If bleeding is difficult, it may be necessary to let i. Repeat steps (e) to (h) until all of the air bub-
the brake fluid settle for a few hours. Repeat bles have disappeared from the brake fluid in
the bleeding procedure when the tiny bubbles the plastic hose.
in the hose have disappeared. j. Tighten the bleed screw to specification.
2. Bleed: Bleed screw (front brake caliper)
• Hydraulic brake system 6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Bleed screw (rear brake caliper)

a. Fill the brake fluid reservoir to the proper level 6 Nm (0.6 m·kg, 4.3 ft·lb)
with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder k. Fill the brake fluid reservoir to the proper level
reservoir or brake fluid reservoir). with the recommended brake fluid.
c. Connect a clear plastic hose “1” tightly to the Refer to “CHECKING THE BRAKE FLUID
bleed screw “2”. LEVEL” on page 3-21.
3-24
CHASSIS
EWA13110
b. Turn the shift rod “2” in direction “a” or “b” until
WARNING the specified installed shift rod length is ob-
After bleeding the hydraulic brake system, tained.
check the brake operation.
Direction “a”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installed shift rod length increases.
3. Install: Direction “b”
• Rider seat Installed shift rod length decreases.
EAS21380 NOTE:
ADJUSTING THE SHIFT PEDAL • Make sure that the exposed thread length “c”
NOTE: between the locknut and joint on both ends of
The shift pedal position is determined by the in- the shift rod is 10 mm or less (for XV19S(C)/
stalled shift rod length “a”. XV19M(C)/ XV19CTS(C)/ XV19CTM(C)).
• Make sure that the exposed thread length “c”
1. Measure: between the locknut and joint on both ends of
• Installed shift rod length “a” the shift rod is 7 mm (for XV19CS(C)/
Incorrect → Adjust. XV19C(C)).
Installed shift rod length
A
XV19S(C)/ XV19M(C)/ 1
XV19CTS(C)/ XV19CTM(C): a c
312.0–316.0 mm (12.28–12.44 in)
b
345.0–349.0 mm (13.58–13.74 in)
2
c
A
a B
1
a c
b 2
c
B
a A. For XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C)
B. For XV19CS(C)/ XV19C(C)
c. Tighten both locknuts.
Locknut (shift rod)

12 Nm (1.2 m·kg, 8.7 ft·lb)
T.

R.
XV19CTM(C)
B. For XV19CS(C)/ XV19C(C) d. Make sure the installed shift rod length is
within specification.
2. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Installed shift rod length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts “1”.
3-25
CHASSIS
EAS21430
ADJUSTING THE DRIVE BELT SLACK NOTE:
NOTE:
• The level marks of the level window on the low-
er drive belt cover are in units of 5 mm (0.20 in).
The drive belt slack must be checked at the tight-
Use them as a standard for measuring the
est point on the belt.
drive belt slack.
ECA14950
• Measure the drive belt slack when the drive
CAUTION: belt has been pushed with 4.5 kg (10 lbs) of
A drive belt that is too tight will overload the pressure using a belt tension gauge “1”.
engine and other vital parts, and one that is
too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive belt slack within the specified lim-
its.
NOTE:
Measure the drive belt slack when the engine is
cold, and when the drive belt is dry. 1
EWA13120
WARNING 3. Remove:
Securely support the vehicle so that there is • Muffler
no danger of it falling over. Refer to “ENGINE REMOVAL” on page 5-1.
4. Adjust:
NOTE: • Drive belt slack
Place the vehicle on the sidestand and or on a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
suitable stand so that the rear wheel is elevated. NOTE:
Place the vehicle on a suitable stand so that the
2. Check:
rear wheel is elevated.
• Drive belt slack “a”
Out of specification → Adjust. a. Loosen the wheel axle nut “1”.
1
b. Loosen both locknuts “2”.
Drive belt slack (on the side- c. Turn both adjusting bolts “3” in direction “a” or
stand) “b” until the specified drive belt slack is ob-
7.5–13 mm (0.30–0.51 in) tained.
Drive belt slack (on a suitable
stand) Direction “a”
14–21 mm (0.55–0.83 in) Drive belt is tightened.
Direction “b”
Belt tension gauge Drive belt is loosened.
90890-03170
Rear drive belt tension gauge
YM-03170
3-26
CHASSIS
b
3 2
NOTE: 3. Remove:
Using the alignment marks on each side of the • Upper bracket
swingarm, make sure that both belt pullers are in Refer to “FRONT FORK” on page 4-66.
the same position for proper wheel alignment. 4. Adjust:
• Steering head
d. Tighten the locknuts to specification. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer “1”, the upper ring
Locknut (drive belt adjusting nut “2”, and the rubber washer “3”.
bolt)
T.
R.
16 Nm (1.6 m·kg, 11 ft·lb)
e. Tighten the rear wheel axle nut to specifica-

tion.
Rear wheel axle nut

150 Nm (15.0 m·kg, 110 ft·lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• Muffler b. Loosen the lower ring nut “4”, and then tight-
Refer to “ENGINE REMOVAL” on page 5-1. en it to the specified torque with a steering nut
EWA12800 wrench “5”.
WARNING NOTE:
Always use a new gasket. Set a torque wrench at a right angle to the steer-
ing nut wrench.
EAS21510
CHECKING AND ADJUSTING THE

STEERING HEAD Steering nut wrench
1. Stand the vehicle on a level surface. 90890-01403
EWA13120 Spanner wrench
WARNING YU-33975
Securely support the vehicle so that there is
no danger of it falling over. Lower ring nut (initial tightening
torque)
T.
NOTE:
R.
52 Nm (5.2 m·kg, 37 ft·lb)

front wheel is elevated.
2. Check:
• Steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3-27
CHASSIS
EAS21530
CHECKING THE FRONT FORK

EWA13120
WARNING
no danger of it falling over.
2. Check:
• Inner tube
Damage/scratches → Replace.
c. Loosen the lower ring nut completely, and • Oil seal
then tighten it to specification with a steering Oil leakage → Replace.
nut wrench. 3. Hold the vehicle upright and apply the front
EWA13140 brake.
WARNING 4. Check:
Do not overtighten the lower ring nut. • Front fork operation
Push down hard on the handlebar several
Lower ring nut (final tightening times and check if the front fork rebounds
torque) smoothly.
T.
Rough movement → Repair.

R.
18 Nm (1.8 m·kg, 13 ft·lb)

Refer to “FRONT FORK” on page 4-66.
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-77.
e. Install the rubber washer “3”.
f. Install the upper ring nut.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper EAS21590
ring nut until their slots are aligned. ADJUSTING THE REAR SHOCK ABSORBER
h. Install the lock washer “1”. ASSEMBLY
EWA13120
NOTE:
WARNING
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
Spring preload
ECA13590
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Spring preload
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Adjust the spring preload with the special
5. Install: wrench “1”.
• Upper bracket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT FORK” on page 4-66. a. Loosen the locknut “2”.
3-28
CHASSIS
b. Turn the adjusting ring “3” in direction “a” or c. Tighten the locknut to specification.
“b”.
Locknut (rear shock absorber
Direction “a” spring preload adjusting nut)
T.
R.
Spring preload is increased (suspen- 30 Nm (3.0 m·kg, 22 ft·lb)
sion is harder).
ECA13600
Direction “b”
CAUTION:
Spring preload is decreased (suspen-
sion is softer). Always tighten the locknut against the ad-
justing nut and torque it to specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Spring preload adjusting posi-
tions EAS21650
Installed spring length CHECKING THE TIRES

Minimum The following procedure applies to both of the
XV19S(C)/ XV19M(C)/ tires.
XV19CTS(C)/ XV19CTM(C): 1. Check:
162.0 mm (6.38 in) • Tire pressure
XV19CS(C)/ XV19C(C): Out of specification → Regulate.
163.0 mm (6.42 in)
Standard
XV19S(C)/ XV19M(C):
171.0 mm (6.73 in)
165.0 mm (6.50 in)
172.0 mm (6.77 in)
Maximum
XV19S(C)/ XV19M(C)/
171.0 mm (6.73 in) EWA13180
XV19CS(C)/ XV19C(C): WARNING

172.0 mm (6.77 in) • The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
1
• The tire pressure and the suspension must
a be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
b • Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
c. Installed spring length
3-29
CHASSIS
Tire air pressure (measured on

cold tires)
Loading condition
0–90 kg (0–198 lb)
Front
250 kPa (36 psi) (2.50 kgf/cm²)
Rear
280 kPa (41 psi) (2.80 kgf/cm²)
Loading condition
XV19S(C)/ XV19M(C):
90–210 kg (198–463 lb) 1. Tire tread depth
XV19CTS(C)/ XV19CTM(C): 2. Side wall
90–186 kg (198–410 lb) 3. Wear indicator
XV19CS(C)/ XV19C(C)
EWA14080
90–204 kg (198–450 lb)
Front WARNING
250 kPa (36 psi) (2.50 kgf/cm²) • Do not use a tubeless tire on a wheel de-
Rear signed only for tube tires to avoid tire fail-
280 kPa (41 psi) (2.80 kgf/cm²) ure and personal injury from sudden
High-speed riding deflation.
Front • When using a tube tire, be sure to install the
250 kPa (36 psi) (2.50 kgf/cm²) correct tube.
Rear • Always replace a new tube tire and a new
280 kPa (41 psi) (2.80 kgf/cm²)
tube as a set.
Maximum load
XV19S(C)/ XV19M(C): • To avoid pinching the tube, make sure the
210 kg (463 lb) wheel rim band and tube are centered in the
XV19CTS(C)/ XV19CTM(C): wheel groove.
186 kg (410 lb) • Patching a punctured tube is not recom-
XV19CS(C)/ XV19C(C): mended. If it is absolutely necessary to do
204 kg (450 lb) so, use great care and replace the tube as
* Total weight of rider, passenger, cargo soon as possible with a good quality re-
and accessories placement.
EWA13190
WARNING
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.
Wear limit (front)

1.0 mm (0.04 in) A. Tire
Wear limit (rear) B. Wheel
1.0 mm (0.04 in)
Tube wheel Tube tire only
Tubeless wheel Tube or tubeless tire
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
3-30
CHASSIS
should always be by the same manufacturer • Install the tire with the mark pointing in the di-
and of the same design. No guarantee con- rection of wheel rotation.
cerning handling characteristics can be giv- • Align the mark “2” with the valve installation
en if a tire combination other than one point.
approved by Yamaha is used on this vehicle.
Front tire
Size
XV19S(C)/ XV19M(C)/
130/70R18M/C 63H
120/70–21M/C 62H
Manufacturer/model
XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C): EAS21670
DUNLOP/D251F CHECKING THE WHEELS

Manufacturer/model The following procedure applies to both of the
XV19S(C)/ XV19M(C)/ wheels.
XV19CTS(C)/ XV19CTM(C): 1. Check:
BRIDGESTONE/G851 RADIAL G • Wheel
Manufacturer/model Damage/out-of-round → Replace.
XV19CS(C)/ XV19C(C): EWA13260
METZELER/880 MARATHON WARNING
Never attempt to make any repairs to the
Rear tire wheel.
Size
NOTE:
XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C): After a tire or wheel has been changed or re-
190/60R17M/C 78H placed, always balance the wheel.
210/40R18M/C 73H EAS21690
Manufacturer/model CHECKING AND LUBRICATING THE

XV19S(C)/ XV19M(C)/ CABLES
XV19CTS(C)/ XV19CTM(C): The following procedure applies to all of the in-
DUNLOP/D251 ner and outer cables.
Manufacturer/model EWA13270
XV19S(C)/ XV19M(C)/ WARNING

XV19CTS(C)/ XV19CTM(C): Damaged outer cable may cause the cable to
BRIDGESTONE/G850 RADIAL G corrode and interfere with its movement. Re-
Manufacturer/model place damaged outer cable and inner cables
XV19CS(C)/ XV19C(C): as soon as possible.
1. Check:
EWA13210
• Outer cable
WARNING Damage → Replace.
New tires have a relatively low grip on the 2. Check:
road surface until they have been slightly • Cable operation
worn. Therefore, approximately 100 km Rough movement → Lubricate.
should be traveled at normal speed before
any high-speed riding is done. Recommended lubricant
Engine oil or a suitable cable lu-
NOTE: bricant
For tires with a direction of rotation mark “1”:
3-31
CHASSIS
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
EAS21700
LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Recommended lubricant
Silicone grease
EAS1D77003
LUBRICATING THE PEDALS

moving parts of the pedal.
Lithium-soap-based grease
EAS21720
LUBRICATING THE SIDESTAND

moving parts of the sidestand.
EAS21740
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
NOTE:
Lubricate the pivoting points and contact surfac-
es between the connecting rod and frame and
between the swingarm and frame.
3-32
ELECTRICAL SYSTEM
EAS21750
ELECTRICAL SYSTEM
EAS21760
CHECKING AND CHARGING THE BATTERY 1

Refer to “ELECTRICAL COMPONENTS” on
page 7-67.
EAS21770
CHECKING THE FUSES

Refer to “ELECTRICAL COMPONENTS” on
page 7-67.
5. Replace:
EAS21790 • Low beam headlight bulb
REPLACING THE HEADLIGHT BULBS (for ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
XV19S(C)/ XV19M(C)/ XV19CTS(C)/ a. Disconnect:
XV19CTM(C)) • Headlight coupler “1”
1. Remove: b. Remove:
• Windshield (for XV19CTS(C)/ XV19CTM(C)) • Headlight bulb “2”
Refer to “GENERAL CHASSIS” on page 4-1. EWA13320
2. Remove: WARNING
• Headlight cover “1” Since the headlight bulb gets extremely hot,
keep flammable products and your hands
1 away from the bulb until it has cooled down.
1
3. Disconnect:
• Air temperature sensor coupler “1”
c. Install:
1 • Headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
ECA13690
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
4. Remove:
affected. If the headlight bulb gets soiled,
• Headlight lens unit “1”
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
d. Connect:
• Headlight coupler
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Replace:
• High beam headlight bulb
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove:
3-33
ELECTRICAL SYSTEM
• Headlight bulb cover “1” 7. Install:

• Headlight lens unit
8. Connect:
• Air temperature sensor coupler
9. Install:
• Headlight cover
Headlight cover bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
1 10.Install:
• Windshield (for XV19CTS(C)/ XV19CTM(C))
b. Disconnect:
• Headlight coupler “1”
c. Detach: EAS1D77005
• Headlight bulb holder “2” REPLACING THE HEADLIGHT BULB (for

1. Remove:
• Headlight lens unit “1”
2
1
d. Remove:
• Headlight bulb
EWA13320
WARNING
2. Disconnect:
Since the headlight bulb gets extremely hot, • Headlight coupler “1”
keep flammable products and your hands 3. Remove:
away from the bulb until it has cooled down. • Headlight bulb cover “2”
e. Install:
• Headlight bulb New
light bulb holder.
ECA13690
CAUTION:
light bulb to keep it free from oil, otherwise
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled, 4. Detach:
thoroughly clean it with a cloth moistened • Headlight bulb holder “1”
with alcohol or lacquer thinner. 5. Remove:
f. Attach: • Headlight bulb “2”
EWA13320
• Headlight bulb holder WARNING
g. Connect:
Since the headlight bulb gets extremely hot,
h. Install:
away from the bulb until it has cooled down.
• Headlight bulb cover
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-34
ELECTRICAL SYSTEM
a b
1
6. Install: B
• Headlight bulb New

light bulb holder.
ECA13690
CAUTION: b a
light bulb to keep it free from oil, otherwise 1
bulb and the luminous flux will be adversely A. For XV19S(C)/ XV19M(C)/ XV19CTS(C)/
affected. If the headlight bulb gets soiled, XV19CTM(C)
thoroughly clean it with a cloth moistened B. For XV19CS(C)/ XV19C(C)
with alcohol or lacquer thinner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Attach:
2. Adjust:
• Headlight bulb holder
• Headlight beam (horizontally)
8. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Headlight bulb cover a. Turn the adjusting bolt “1” in direction “a” or
9. Connect: “b”.
10.Install: Direction “a”
• Headlight lens unit Headlight beam moves to the right.
Direction “b”
EAS21810
Headlight beam moves to the left.
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
Direction “a”
Headlight beam is raised.
Direction “b”
Headlight beam is lowered.
3-35
ELECTRICAL SYSTEM
b
a 1
b a

XV19CTM(C)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-36
ELECTRICAL SYSTEM
3-37
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
REMOVING THE WINDSHIELD ............................................................... 4-2
ASSEMBLING THE WINDSHIELD ........................................................... 4-2
INSTALLING THE WINDSHIELD.............................................................. 4-2
REMOVING THE BACKREST ..................................................................4-5
ASSEMBLING THE BACKREST............................................................... 4-5
INSTALLING THE BACKREST .................................................................4-5
CHECKING THE SIDEBAG BRACKET SPRING NUTS........................... 4-8
FRONT WHEEL............................................................................................. 4-18

REMOVING THE FRONT WHEEL.......................................................... 4-22
DISASSEMBLING THE FRONT WHEEL................................................ 4-22
CHECKING THE FRONT WHEEL .......................................................... 4-22
ASSEMBLING THE FRONT WHEEL......................................................4-23
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-23
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-24
REAR WHEEL ...............................................................................................4-27

REMOVING THE REAR WHEEL (DISC) ................................................ 4-32
DISASSEMBLING THE REAR WHEEL .................................................. 4-32
4
CHECKING THE REAR WHEEL............................................................. 4-32
CHECKING THE REAR BRAKE CALIPER BRACKET........................... 4-32
CHECKING THE REAR WHEEL DRIVE HUB ........................................ 4-33
CHECKING AND REPLACING THE REAR WHEEL PULLEY ............... 4-33
ASSEMBLING THE REAR WHEEL ........................................................ 4-33
ADJUSTING THE REAR WHEEL STATIC BALANCE............................ 4-33
INSTALLING THE REAR WHEEL (DISC)............................................... 4-33
FRONT BRAKE ............................................................................................. 4-35

INTRODUCTION .....................................................................................4-40
CHECKING THE FRONT BRAKE DISCS............................................... 4-40
REPLACING THE FRONT BRAKE PADS .............................................. 4-41
REMOVING THE FRONT BRAKE CALIPERS ....................................... 4-42
DISASSEMBLING THE FRONT BRAKE CALIPERS..............................4-42
CHECKING THE FRONT BRAKE CALIPERS ........................................ 4-43
ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 4-43
INSTALLING THE FRONT BRAKE CALIPERS ...................................... 4-43
REMOVING THE FRONT BRAKE MASTER CYLINDER .......................4-44
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 4-45
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 4-45
INSTALLING THE FRONT BRAKE MASTER CYLINDER......................4-45
REAR BRAKE ...............................................................................................4-47
INTRODUCTION .....................................................................................4-53
CHECKING THE REAR BRAKE DISC....................................................4-53
REPLACING THE REAR BRAKE PADS................................................. 4-53
REMOVING THE REAR BRAKE CALIPER ............................................4-54
DISASSEMBLING THE REAR BRAKE CALIPER ..................................4-54
CHECKING THE REAR BRAKE CALIPER............................................. 4-55
ASSEMBLING THE REAR BRAKE CALIPER ........................................ 4-55
INSTALLING THE REAR BRAKE CALIPER...........................................4-55
REMOVING THE REAR BRAKE MASTER CYLINDER ......................... 4-56
CHECKING THE REAR BRAKE MASTER CYLINDER .......................... 4-57
ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................4-57
INSTALLING THE REAR BRAKE MASTER CYLINDER ........................ 4-57
HANDLEBAR ................................................................................................4-59
REMOVING THE HANDLEBAR..............................................................4-63
CHECKING THE HANDLEBAR ..............................................................4-63
INSTALLING THE HANDLEBAR ............................................................ 4-63
FRONT FORK................................................................................................4-66
REMOVING THE FRONT FORK LEGS.................................................. 4-71
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-71
CHECKING THE FRONT FORK LEGS .................................................. 4-72
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-72
INSTALLING THE FRONT FORK LEGS (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C)) .................................................................. 4-75
INSTALLING THE FRONT FORK LEGS (for XV19CS(C)/ XV19C(C))... 4-76
STEERING HEAD.......................................................................................... 4-77

REMOVING THE LOWER BRACKET.....................................................4-81
CHECKING THE STEERING HEAD .......................................................4-81
INSTALLING THE STEERING HEAD (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19TMX(C)) .................................................................. 4-81
INSTALLING THE STEERING HEAD (for XV19CS(C)/ XV19C(C)) ....... 4-82
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM ......................4-83

HANDLING THE REAR SHOCK ABSORBER ........................................ 4-86
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-86
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY AND
SWINGARM ........................................................................................... 4-86
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-87
CHECKING THE CONNECTING ARM AND RELAY ARM.....................4-87
CHECKING THE SWINGARM ................................................................4-87
INSTALLING THE RELAY ARM, REAR SHOCK ABSORBER
ASSEMBLY AND CONNECTING ARMS ............................................... 4-87
INSTALLING THE SWINGARM ..............................................................4-89
BELT DRIVE.................................................................................................. 4-90
REMOVING THE DRIVE BELT AND DRIVE PULLEY ........................... 4-92
CHECKING THE DRIVE BELT ...............................................................4-92
INSTALLING THE DRIVE BELT AND DRIVE PULLEY .......................... 4-92
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the windshield (for XV19CTS(C)/ XV19CTM(C))
1 5 23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
LT
LT
6
4 23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
LT
LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
6
LT
2
3
8 Nm (0.8 m • kg, 5.8 ft • Ib) 3

23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
T.
R.
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
Windshield holder bracket assembly (left and
6 2
right)
For installation, reverse the removal proce-
dure.
4-1
GENERAL CHASSIS
ET1D71039
REMOVING THE WINDSHIELD

1. Remove: 1
• Windshield
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Insert the key “1” into the windshield lock, turn
it clockwise and then remove the key.
2
b
2 ET1D71040
1 INSTALLING THE WINDSHIELD
1. Install:
• Right windshield holder bracket assembly “1”
NOTE:
Pass the throttle cables “2” between the front
2. Unlock. fork and the right windshield holder bracket as-
sembly.
b. Remove the windshield by pushing it forward,
and then pulling it upward as shown.
EW1D71016
WARNING
Be careful not to push the vehicle forward
when removing the windshield. The vehicle 2 1
could fall off the sidestand.
EC1D71025
CAUTION:
Securely hold the windshield to prevent it
from falling when removing.
2. Install:
• Windshield
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the slot “a” in each windshield bracket (left
and right side) into its holder “b”.
NOTE:
Make sure that the throttle cables “1” are not
pinched.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71045
a
ASSEMBLING THE WINDSHIELD
1. Install:
• Windshield lock “1” b
NOTE:
1
Align the projection “a” on the lock “1” with the
slot “b” in the windshield bracket “2”. b. Push the windshield backward until it snaps
into place.
4-2
GENERAL CHASSIS
c. Insert the key into the windshield lock, turn it

counterclockwise until it stops to lock the fas-
tener, and then remove the key.
1. Lock
2. Fastener
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-3
GENERAL CHASSIS
Removing the sidebags and backrest (for XV19CTS(C)/ XV19CTM(C))
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
23 Nm (2.3 m • kg, 17 ft • Ib)
4
T.
R.
6
5 3
2
7
1
5
7
1
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
NOTE:
Water can be harmful to untreated leather.
Use Yamaha Saddle Soap or another quality
brand according to the manufacturer’s direc-
1 Sidebag (left and right) 2 tions to clean the leather on the sidebags.
Polish the dry leather with a soft cloth, and
then treat with Yamaha Mink Oil or another
high-quality leather protectant for increased
water resistance.
2 Backrest assembly 1
3 Backrest upper bracket stay 1
4 Backrest pad 1
5 Backrest plate 2
6 Backrest upper bracket 1
7 Backrest lower bracket (left and right) 2
dure.
4-4
GENERAL CHASSIS
ET1D71041
REMOVING THE BACKREST NOTE:

1. Remove: Align the projection “a” on the lock “1” with the
• Backrest slot “b” in the left backrest lower bracket “2”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Open the sidebag lids. a
b. Insert the key “1” into the backrest lock, turn
it counterclockwise, and then remove the 1
key.
2 b
2. Install:
• Backrest lower brackets “1”
• Backrest upper bracket “2”
1 • Backrest plate
NOTE:
2. Unlock.
Before tightening the bolts “3” to specification,
c. Pull the lever “1” on each side of the backrest temporarily install the backrest lower brackets
upward. on the backrest holders, making sure not to push
down on the rear of the brackets. The lower bolts
cannot be tightened when the backrest lower
brackets are installed completely.
1
1
1
d. While holding the levers in the upward posi- 3
tion, lift the backrest upward and remove it by
pulling it to the rear.
ET1D71042
INSTALLING THE BACKREST

1. Install:
• Backrest
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the slot “a” on each backrest bracket (left
and right side) into the groove of its holder “b”.
EC1D71026
CAUTION:
Be careful not to scratch the rear fender
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ when fitting the slot into the groove.
ET1D71046
ASSEMBLING THE BACKREST

1. Install:
• Backrest lock “1”
4-5
GENERAL CHASSIS
b. Push the rear of the backrest down smoothly

but forcefully to lock it in place and make sure
that the lever hook “1” on each side is secure-
ly fit over its holder “2”.
EW1D71017
WARNING
Both lever hooks must be securely fitted
over their holder. If the backrest is loose, a
passenger might lose balance and fall.
2
c. Insert the key into the backrest lock, turn it
clockwise, and then remove the key.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-6
GENERAL CHASSIS
Removing the sidebag brackets (for XV19CTS(C)/ XV19CTM(C))
48 Nm (4.8 m • kg, 35 ft • Ib)
T.
R.
4
TLT
L
4 3
LT
LT
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.
48 Nm (4.8 m • kg, 35 ft • Ib)

T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.

Refer to “GENERAL CHASSIS” on page
Sidebag/Backrest 4-1.
1 Passenger footrest (left and right) 2
2 Sidebag bracket brace 1
NOTE:
3 Sidebag bracket (left and right) 2 Remove only one sidebag bracket at a time.
If both brackets are removed at the same
time, the rear fender will fall.
NOTE:
4 O2 sensor lead guide 1
Pass the O2 sensor lead through the guide.

dure.
4-7
GENERAL CHASSIS
ET1D71047
CHECKING THE SIDEBAG BRACKET

SPRING NUTS
1. Check:
• Sidebag bracket spring nut height “a”
Out of specification → Adjust.
Sidebag bracket spring nut

height
12.0 mm (0.47 in)
2. Check:
• Sidebag bracket spring nuts
Damage → Replace.
4-8
GENERAL CHASSIS
Removing the seats and side covers
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
2
3
1
T.
R. 7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
6
23 Nm (2.3 m • kg, 17 ft • Ib) 4

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
LT
LT
7
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R
LT 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

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
dure.
4-9
GENERAL CHASSIS
Removing the headlight (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
2
3
13
10
10
9 7
8
6 5
12
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

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) coupler 1 Disconnect.
6 Headlight lens unit 1
7 Front left turn signal/position light coupler 1 Disconnect.
8 Front right turn signal/position light coupler 1 Disconnect.
9 Wire harness stopper bracket 1
10 Left handlebar switch coupler 4 Disconnect.
11 Right handlebar switch coupler 3 Disconnect.
12 Main switch coupler 2 Disconnect.
13 Headlight body 1
dure.
4-10
GENERAL CHASSIS
Removing the headlight (for XV19CS(C)/ XV19C(C))
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
11
10
8
7 6
9
11
3
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4
10
2 5 LT
16 Nm (1.6 m • kg, 11 ft • Ib)

T.
R.
1 LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

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 switch coupler 2 Disconnect.
6 Headlight body 1
7 Air temperature sensor coupler 1 Disconnect.
8 Air temperature sensor bracket 1
9 Air temperature sensor 1
10 Headlight bracket 2
11 Spacer 4
dure.
4-11
GENERAL CHASSIS
Removing the battery
4 6 1
5 10
2
7 9
17 16 3
18
15
13 (3)
11
14
19
12 20
19

Tool kit tray/Seat bracket 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 lead 1 Disconnect.
7 Battery 1
8 Battery band 1
9 Sub-wire harness 1 1 Disconnect.
10 Main fuse 1
11 Plastic locking tie 1
12 Fuse box 1
13 Starter relay coupler 1 Disconnect.
14 Starter relay 1
For XV19S(C)/ XV19M(C)/ XV19CTS(C)/
15 Diode 1 1 XV19CTM(C)
4-12
GENERAL CHASSIS
Removing the battery
4 6 1
5 10
2
7 9
17 16 3
18
15
13 (3)
11
14
19
12 20
19

16 Relay unit 1
17 Headlight relay 1
18 Turn signal relay 1
19 Plastic locking tie 2
20 Battery box 1
dure.
4-13
GENERAL CHASSIS
Removing the air filter case (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
R.
T.
R.
(7)
9 15
1
2
10
6 7
5
13
16
12 14
17
16
3
11

Rider seat 4-1.
Fuel tank Refer to “FUEL TANK” on page 6-1.
Pressure regulator cover Refer to “THROTTLE BODIES” on page 6-7.
1 Air filter case cover 1
2 Air filter element 1
3 Cylinder-#1 intake air pressure sensor coupler 1 Disconnect.
4 Cylinder-#1 intake air pressure sensor hose 1 Disconnect.
5 Cylinder-#1 intake air pressure sensor 1
6 Cylinder-#1 intake air pressure sensor bracket 1
11 Cylinder head breather hose 1 Disconnect.
12 Air filter case breather hose 1 1 Disconnect.
14 ISC (idle speed control) unit inlet hose 1 Disconnect.
4-14
GENERAL CHASSIS
Removing the air filter case (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
T. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
R.
T.
R.
(7)
9 15
1
2
10
6 7
5
13
16
12 14
17
16
3
11

15 Air filter case bracket 1
16 Air filter case joint clamp screw 2 Loosen.
17 Air filter case 1
dure.
4-15
GENERAL CHASSIS
Removing the air filter case (for XV19CS(C)/ XV19C(C))
10 Nm (1.0 m • kg, 7.2 ft • Ib) 17 Nm (1.7 m • kg, 12 ft • Ib)
T.
T.
R.
R.
2
1 16 Nm (1.6 m • kg, 11 ft • Ib)
2
T.
R.
1 (7) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
4
5
12 19 18
13
20
3
10 Nm (1.0 m • kg, 7.2 ft • Ib) New
T.
R.
9
8
21 16
10
11
15 17
22
21
6
14

Rider seat 4-1.
Pressure regulator cover Refer to “THROTTLE BODIES” on page 6-7.
3 Coupler holder 1
4 Air filter case cover 1
5 Air filter element 1
14 Cylinder head breather hose 1 Disconnect.
4-16
GENERAL CHASSIS
Removing the air filter case (for XV19CS(C)/ XV19C(C))
T.
T.
R.
R.
2
1 16 Nm (1.6 m • kg, 11 ft • Ib)
2
T.
R.
1 (7) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
4
5
12 19 18
13
20
3
10 Nm (1.0 m • kg, 7.2 ft • Ib) New
T.
R.
9
8
21 16
10
11
15 17
22
21
6
14

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 screw 2 Loosen.
22 Air filter case 1
dure.
4-17
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
T.
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R
T.
8
R.
LT
T.
R.
9 4
5 LT
1 7 10
4
6
9
LT (4) LT 11
8
LT 16 Nm (1.6 m • kg, 11 ft • Ib) 10
T.
R.
3 LT
12
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
14 72 Nm (7.2 m • kg, 52 ft • Ib)
T.
15
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
16
(6) LT
2
LT
16
LT
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
13 14
LT
23 Nm (2.3 m • kg, 17 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
(6)
T.
R.
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 1
3 Front fender stay rod 1
4 Front brake hose guide 2
5 Right front brake hose guide bracket 1
6 Left front brake hose guide bracket 1
7 Front fender 1
8 Reflector 2
9 Reflector bracket 2
10 Front brake caliper 2
11 Front wheel axle pinch bolt 1 Loosen.
12 Front wheel axle 1
13 Front wheel 1
4-18
FRONT WHEEL
Removing the front wheel and brake discs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
T.
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R
T.
8
R.
LT
T.
R.
9 4
5 LT
1 7 10
4
6
9
LT (4) LT 11
8
LT 16 Nm (1.6 m • kg, 11 ft • Ib) 10
T.
R.
3 LT
12
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
14 72 Nm (7.2 m • kg, 52 ft • Ib)
T.
15
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
16
(6) LT
2
LT
16
LT
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
13 14
LT
23 Nm (2.3 m • kg, 17 ft • Ib)
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
(6)
T.
R.

14 Collar 2
15 Front brake disc cover 1
16 Front brake disc 2
dure.
4-19
FRONT WHEEL
Removing the front wheel and brake discs (for XV19CS(C)/ XV19C(C))
LT
4
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
3 LT 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
6 (4)
T.
R.
2
5 1
9 7 LT
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
72 Nm (7.2 m • kg, 52 ft • lb)

T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib) 8

T.
R.
LT
11
1
(5) 5
12 7
LT 6
12
LT
11
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
10 (5) 23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.
NOTE:
the front wheel is elevated.
1 Front brake hose holder 2

2 Right front brake hose holder bracket 1
3 Left front brake hose holder bracket 1
4 Front fender 1
5 Reflector 2
8 Front wheel axle pinch bolt 1 Loosen.
9 Front wheel axle 1
10 Front wheel 1
11 Collar 2
12 Front brake disc 2
dure.
4-20
FRONT WHEEL
Disassembling the front wheel
New 1
2
LS
3
2
1 New
LS

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1
For assembly, reverse the disassembly pro-
cedure.
4-21
FRONT WHEEL
EAS21900 EAS21910
REMOVING THE FRONT WHEEL DISASSEMBLING THE FRONT WHEEL

1. Stand the vehicle on a level surface. 1. Remove:
EWA13120
• Oil seals
WARNING • Wheel bearings
Securely support the vehicle so that there is ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
no danger of it falling over. a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flathead
screwdriver.
• Right front fender stay “1” NOTE:
• Left front fender stay “2” To prevent damaging the wheel, place a rag “2”
• Front fender stay rod “3” between the screwdriver and the wheel surface.
NOTE:
• Remove the right front fender stay bolts and
left front fender stay bolt (rear side), then hold
the rod with a wrench “4” and remove the left
front fender stay bolt (front side) “5”.
• Remove the rod from the right side of the vehi-
cle.
c. Remove the wheel bearings “3” with a gener-

al bearing puller.
3
2
1 5
4
3. Loosen:
• Front wheel axle pinch bolt “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21920
CHECKING THE FRONT WHEEL

1. Check:
• Front wheel axle
1 Roll the wheel axle on a flat surface.
Bends → Replace.
EWA13460
4. Remove: WARNING
• Front brake calipers Do not attempt to straighten a bent wheel ax-
NOTE: le.
Do not apply the brake lever when removing the
brake calipers.
5. Elevate:
• Front wheel
NOTE:
front wheel is elevated.
4-22
FRONT WHEEL
EAS21960
ASSEMBLING THE FRONT WHEEL

1. Install:
• Wheel bearings New
• Oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seals in
the reverse order of disassembly.
EC1D71011
CAUTION:
2. Check: Do not contact the wheel bearing inner race
• Tire “1” or balls “2”. Contact should be made
• Front wheel only with the outer race “3”.
Damage/wear → Replace. NOTE:
Refer to “CHECKING THE TIRES” on page
Use a socket “4” that matches the diameter of
3-29 and “CHECKING THE WHEELS” on
the wheel bearing outer race and oil seal.
page 3-31.
3. Measure:
• Radial wheel runout “1”
• Lateral wheel runout “2”
Over the specified limits → Replace.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21970
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
NOTE:
• After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
4. Check:
1. Remove:
• Wheel bearings
• Balancing weight(s)
Front wheel turns roughly or is loose → Re-
2. Find:
place the wheel bearings.
• Front wheel’s heavy spot
• Oil seals
Damage/wear → Replace. NOTE:
Place the front wheel on a suitable balancing
stand.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
b. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
4-23
FRONT WHEEL
c. Turn the front wheel 90° so that the “X1” mark c. If the heavy spot does not stay in that posi-
is positioned as shown. tion, install a heavier weight.
d. Release the front wheel. d. Repeat steps (b) and (c) until the front wheel
e. When the wheel stops, put an “X2” mark at is balanced.
the bottom of the wheel. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• Front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
f. Repeat steps (d) through (f) several times un-

til all the marks come to rest at the same spot.
g. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b. If the front wheel does not remain stationary
3. Adjust:
at all of the positions, rebalance it.
• Front wheel static balance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight “1” onto the rim ex- EAS22000
actly opposite the heavy spot “X”. INSTALLING THE FRONT WHEEL (FRONT
NOTE:
BRAKE DISCS)
The following procedure applies to both of the
Start with the lightest weight.
front brake discs.
1. Install:
• Front brake disc
• Front brake disc cover
Front brake disc bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
LOCTITE®
NOTE:
Tighten the front brake disc bolts in stages and
b. Turn the front wheel 90° so that the heavy in a crisscross pattern.
spot is positioned as shown.
4-24
FRONT WHEEL
Front brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)
T.
R.
EWA13500
WARNING
Make sure the brake hose is routed properly.
7. Install:
• Front fender
• Left front brake hose guide bracket
2. Check: • Right front brake hose guide bracket
• Front brake discs NOTE:
Refer to “CHECKING THE FRONT BRAKE • Temporarily tighten the front fender bolts.
DISCS” on page 4-40. • Apply locking agent (LOCTITE®) to the
3. Lubricate: threads of the front fender bolts.
• Oil seal lips
Recommended lubricant XV19CTS(C)/ XV19CTM(C))
Lithium-soap-based grease • Front fender stay rod “1”
• Left front fender stay “2”
4. Install: • Right front fender stay “3”
• Front wheel axle NOTE:
NOTE: • Insert the rod into the front wheel axle from the
Install the tire and wheel with the mark “1” point- right side of the vehicle.
ing in the direction of wheel rotation. • Tighten the left front fender stay bolt (front
side) “4” to specification while holding the rod
with a wrench “5”, and then tighten the left front
fender stay bolt (rear side) and right front fend-
er stay bolts to specification.
5. Tighten:
• Front wheel axle 2
• Front wheel axle pinch bolt 4
5 3
Front wheel axle 9. Tighten:
72 Nm (7.2 m·kg, 52 ft·lb)
T.
• Front fender bolts

R.
Front wheel axle pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb) Front fender bolt
16 Nm (1.6 m·kg, 11 ft·lb)
T.
EC1D71004
R.
CAUTION: LOCTITE®
Before tightening the wheel axle, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
6. Install:
• Front brake calipers
4-25
FRONT WHEEL
4-26
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear fender
4
1
LT
LT
4 2
LT
LT
4
4
2
3
23 Nm (2.3 m • kg, 17 ft • Ib) 40 Nm (4.0 m • kg, 29 ft • Ib)

T.
T.
R.
R.

T.
T.
R.
R.

Rider seat/Passenger seat/Tool kit tray 4-1.
1 Sub-wire harness 1 coupler 1 Disconnect.
2 Rear fender bracket 2 XV19CTM(C)
3 Rear fender bracket 2 For XV19CS(C)/ XV19C(C)
4 Dowel pin 4
5 Rear fender assembly 1
dure.
4-27
REAR WHEEL
Removing the rear wheel
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
150 Nm (15.0 m • kg, 110 ft • lb)
T.
R.
6
5 27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
10
8 7
1 S
6
5
11 3
9 2
4
LS
12
4
13
S
14
15
NOTE:
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 Drive belt adjusting locknut 2 Loosen.
6 Drive belt adjusting bolt 2 Loosen.
7 Rear wheel axle nut 1
8 Washer 1
9 Rear wheel axle 1
10 Right drive belt puller 1
11 Left drive belt puller 1
12 Rear brake caliper bracket 1
13 Collar 1 Black
4-28
REAR WHEEL
Removing the rear wheel
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
150 Nm (15.0 m • kg, 110 ft • lb)
T.
R.
6
5 27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
10
8 7
1 S
6
5
11 3
9 2
4
LS
12
4
13
S
14
15

14 Collar 1 Silver
15 Rear wheel 1
dure.
4-29
REAR WHEEL
Removing the rear brake disc and rear wheel drive hub

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 damper 6
12 Rear wheel 1
dure.
4-30
REAR WHEEL
Disassembling the rear wheel
New 4 5
6
LS
3
2
1

1 Collar 1
2 Bearing 1
3 Spacer 1
4 Oil seal 1
5 Circlip 1
6 Bearing 1
cedure.
4-31
REAR WHEEL
EAS28760
REMOVING THE REAR WHEEL (DISC)

1. Stand the vehicle on a level surface. 1
EWA13120
WARNING
2
NOTE:
rear wheel is elevated.
EAS22080
2. Remove: DISASSEMBLING THE REAR WHEEL
• Rear brake caliper “1” 1. Remove:
NOTE: • Oil seals
Do not depress the brake pedal when removing • Wheel bearings
the brake caliper. Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-22.
EAS22090
CHECKING THE REAR WHEEL

1. Check:
• Rear wheel axle
• Rear wheel
• Wheel bearings
1 • Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-22.
3. Loosen: 2. Check:
• Drive belt adjusting locknuts “1” • Tire
• Drive belt adjusting bolts “2” • Rear 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
• Lateral wheel runout
2 1 Refer to “CHECKING THE FRONT WHEEL”
on page 4-22.
Radial wheel runout limit

4. Remove:
1.0 mm (0.04 in)
• Rear wheel axle nut “1” Lateral wheel runout limit
• Rear wheel axle “2” 0.5 mm (0.02 in)
• Rear wheel
NOTE: ET1D71024
Push the rear wheel forward and remove the CHECKING THE REAR BRAKE CALIPER
drive belt from the rear wheel pulley. BRACKET
1. Check:
• Rear brake caliper bracket
4-32
REAR WHEEL
EAS22110 EAS22150
CHECKING THE REAR WHEEL DRIVE HUB ADJUSTING THE REAR WHEEL STATIC
1. Check: BALANCE
• Rear wheel drive hub NOTE:
Cracks/damage → Replace. • After replacing the tire, wheel or both, the rear
• Rear wheel drive hub dampers wheel static balance should be adjusted.
Damage/wear → Replace. • Adjust the rear wheel static balance with the
EAS22130 brake disc and rear wheel drive hub installed.
CHECKING AND REPLACING THE REAR
1. Adjust:
WHEEL PULLEY
• Rear wheel static balance
1. Check:
Refer to “ADJUSTING THE FRONT WHEEL
• Rear wheel pulley
STATIC BALANCE” on page 4-23.
Surface plating has come off → Replace the
rear wheel pulley. EAS28770
Bent teeth → Replace the rear wheel pulley. INSTALLING THE REAR WHEEL (DISC)
2. Replace: 1. Lubricate:
• Rear wheel pulley • Rear wheel axle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Oil seal lips
a. Remove the self-locking nuts and the rear
wheel pulley. Recommended lubricant
b. Clean the rear wheel drive hub with a clean Lithium-soap-based grease
cloth, especially the surfaces that contact the
2. Install:
pulley.
• Rear brake disc
c. Install the new rear wheel pulley.
• Rear brake disc cover
Rear wheel pulley self-locking
nut Rear brake disc bolt
T.
18 Nm (1.8 m·kg, 13 ft·lb)

R.
95 Nm (9.5 m·kg, 68 ft·lb)

T.
R.
LOCTITE®
NOTE:
NOTE:
Tighten the self-locking nuts in stages and in a
• Apply locking agent (LOCTITE®) to the
crisscross pattern.
threads of the brake disc bolts.
• Tighten the brake disc bolts in stages and in a
crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
LT
EAS22140
ASSEMBLING THE REAR WHEEL

3. Check:
1. Install:
• Rear brake disc
• Wheel bearings New Refer to “CHECKING THE REAR BRAKE
• Oil seals New DISC” on page 4-53.
Refer to “ASSEMBLING THE FRONT 4. Install:
WHEEL” on page 4-23. • Rear wheel axle
• Washer
• Rear wheel axle nut
4-33
REAR WHEEL
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
Rear wheel axle nut

150 Nm (15.0 m·kg, 110 ft·lb)
T.
R.
7. Install:
• Rear brake caliper
Rear brake caliper

27 Nm (2.7 m·kg, 19 ft·lb)
T.
R.
EWA13500
WARNING
Make sure the brake hose is routed properly.
4-34
FRONT BRAKE
EAS22210
FRONT BRAKE
Removing the front brake pads
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1
LT
4
6 5
40 Nm (4.0 m • kg, 29 ft • Ib) 9
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.
9 7

The following procedure applies to both of
the front brake calipers.
1 Brake hose holder 1
2 Reflector 1
5 Brake pad clip 2
6 Brake pad pin 1
8 Brake pad 2
9 Brake pad shim 2
dure.
4-35
FRONT BRAKE
Removing the front brake master cylinder
S 30 Nm (3.0 m • kg, 22 ft • Ib)
T.
R.
10 9
12 8
9
5 New
7
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Drain.
Brake fluid Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” on page 3-24.
1 Right rearview mirror 1
2 Brake master cylinder reservoir cap 1
Brake master cylinder reservoir diaphragm hold-
3 1
er
4 Brake master cylinder reservoir diaphragm 1
5 Brake lever 1
6 Brake light switch connector 2 Disconnect.
7 Brake light switch 1
8 Front brake hose union bolt 1
9 Copper washer 2
10 Front brake hose 1
11 Front brake master cylinder holder 1
12 Front brake master cylinder 1
dure.
4-36
FRONT BRAKE
Disassembling the front brake master cylinder
3 New
2 New

1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Brake master cylinder body 1
cedure.
4-37
FRONT BRAKE
Removing the front brake calipers
6
7
5
3 New
40 Nm (4.0 m • kg, 29 ft • Ib)

1
.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

T.
R.
LT
4
3 New
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)

.
R.

Drain.
1 Brake hose holder 1
2 Front brake hose union bolt 1
3 Copper washer 2
4 Front brake hose 1
5 Reflector 1
dure.
4-38
FRONT BRAKE
Disassembling the front brake calipers

1 Brake pad clip 2
2 Brake pad pin 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake caliper piston 4
7 Brake caliper piston dust seal 4
8 Brake caliper piston seal 4
9 Bleed screw 1
cedure.
4-39
FRONT BRAKE
EAS22220
e. Measure the deflection 1.5 mm (0.06 in) be-
INTRODUCTION
EWA14100
low the edge of the brake disc.
WARNING
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 entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Never use solvents on internal brake com- 4. Measure:

ponents. • Brake disc thickness
• Use only clean or new brake fluid for clean- Measure the brake disc thickness at a few dif-
ing brake components. ferent locations.
• Brake fluid may damage painted surfaces Out of specification → Replace.
and plastic parts. Therefore, always clean
Brake disc thickness limit
up any spilt brake fluid immediately.
4.5 mm (0.18 in)
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get im-
mediate medical attention.
EAS22240
CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake
discs.
1. Remove:
• Front wheel 5. Adjust:
Refer to “FRONT WHEEL” on page 4-18. • Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check: a. Remove the brake disc.
• Brake disc b. Rotate the brake disc by one bolt hole.
Damage/galling → Replace. c. Install the brake disc.
3. Measure:
• Brake disc deflection Front brake disc bolt
Out of specification → Correct the brake disc 23 Nm (2.3 m·kg, 17ft·lb)
T.
R.
deflection or replace the brake disc. LOCTITE®
Brake disc deflection limit NOTE:

0.10 mm (0.0039 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
threads of the brake disc bolts.
a. Place the vehicle on a suitable stand so that • Tighten the brake disc bolts in stages and in a
the front wheel is elevated. crisscross pattern.
b. Before measuring the front brake disc deflec-
tion, turn the handlebar to the left or right to
ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-40
FRONT BRAKE
d. Measure the brake disc deflection. 2. Install:

e. If out of specification, repeat the adjustment • Brake pad shims
steps until the brake disc deflection is within (onto the brake pads)
specification. • Brake pads
f. If the brake disc deflection cannot be brought • Brake pad spring
within specification, replace the brake disc. NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, brake pad shims,
6. Install: and a brake pad spring as a set.
• Front wheel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT WHEEL” on page 4-18. a. Connect a clear plastic hose “1” tightly to the
EAS22270 bleed screw “2”. Put the other end of the hose
REPLACING THE FRONT BRAKE PADS into an open container.
The following procedure applies to both brake b. Loosen the bleed screw and push the brake
calipers. caliper pistons into the brake caliper with your
NOTE: finger.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- 2
ble the brake caliper. 1
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness (in-

ner)
5.5 mm (0.22 in) c. Tighten the bleed screw.
Limit
0.5 mm (0.02 in) Bleed screw (front brake caliper)
Brake pad lining thickness (out- 6 Nm (0.6 m·kg, 4.3ft·lb)
T.
R.
er)
5.5 mm (0.22 in) d. Install a new brake pad shim onto each new
Limit brake pad.
0.5 mm (0.02 in) e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow mark “a” on the brake pad spring
must point in the direction of disc rotation.
4-41
FRONT BRAKE
• Front brake hose “4”

NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4
3. Install:
• Brake pad pin 2
• Brake pad clips 3
• Front brake caliper
EAS22350
Front brake caliper bolt DISASSEMBLING THE FRONT BRAKE

40 Nm (4.0 m·kg, 29 ft·lb) CALIPERS
T.
R.

4. Check: brake calipers.
• Brake fluid level 1. Remove:
Below the minimum level mark “a” → Add the • Brake caliper pistons “1”
recommended brake fluid to the proper level. • Brake caliper piston seals “2”
Refer to “CHECKING THE BRAKE FLUID • Brake caliper piston dust seals “3”
LEVEL” on page 3-21. EWA1D77007
WARNING
Do not loosen the bolts “4”.
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake sys- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tem. a. Blow compressed air into the brake hose joint
Refer to “BLEEDING THE HYDRAULIC opening “a” to force out the pistons from the
BRAKE SYSTEM” on page 3-24. brake caliper.
EWA13560
EAS22300
WARNING
REMOVING THE FRONT BRAKE CALIPERS
The following procedure applies to both of the • Cover the brake caliper pistons with a rag.
brake calipers. Be careful not to get injured when the pis-
tons are expelled from the brake caliper.
NOTE:
• Never try to pry out the brake caliper pis-
Before removing the brake caliper, drain the tons.
brake fluid from the entire brake system.
1. Remove:
• Brake hose holder “1”
• Front brake hose union bolt “2”
• Copper washers “3”
4-42
FRONT BRAKE
1
a
1
b. Remove the brake caliper piston seals and EAS22410
dust seals. ASSEMBLING THE FRONT BRAKE

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CALIPERS
EWA1D77004
EAS22390
WARNING
CHECKING THE FRONT BRAKE CALIPERS
• Before installation, all internal brake com-
Recommended brake component replace- ponents should be cleaned and lubricated
ment schedule with clean or new brake fluid.
Brake pads If necessary • Never use solvents on internal brake com-
Piston seals Every two years ponents as they will cause the piston seals
and dust seals to swell and distort.
Dust seals Every two years • Whenever a brake caliper is disassembled,
Brake hoses Every four years replace the brake caliper piston seals and
Every two years and dust seals.
Brake fluid whenever the brake
is disassembled Recommended fluid
DOT 4
1. Check:
• Brake caliper pistons “1” EAS22440
Rust/scratches/wear → Replace the brake INSTALLING THE FRONT BRAKE CALIPERS

caliper pistons. The following procedure applies to both of the
• Brake caliper cylinders “2” brake calipers.
Scratches/wear → Replace the brake caliper 1. Install:
assembly. • Front brake caliper “1”
• Brake caliper body “3” (temporarily)
Cracks/damage → Replace the brake caliper • Copper washers New
assembly. • Front brake hose “2”
• Brake fluid delivery passages • Front brake hose union bolt “3”
(brake caliper body)
Obstruction → Blow out with compressed air. Front brake hose union bolt
EWA1D77003
32 Nm (3.2 m·kg, 23 ft·lb)
T.
R.
WARNING
EWA1D77008
Whenever a brake caliper is disassembled,
WARNING
replace the piston seals and dust seals.
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C))” on page 2-51
and “CABLE ROUTING (for XV19CS(C)/
XV19C(C))” on page 2-67.
4-43
FRONT BRAKE
ECA14170
CAUTION: not enter the brake fluid reservoir. Water
When installing the brake hose onto the will significantly lower the boiling point of
brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.
“a” touches the projection “b” on the brake ECA13540
caliper. CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
a 5. Bleed:
• Brake system
2 Refer to “BLEEDING THE HYDRAULIC
b BRAKE SYSTEM” on page 3-24.
3 6. Check:
1 • Brake fluid level
2. Remove: recommended brake fluid to the proper level.
• Front brake caliper Refer to “CHECKING THE BRAKE FLUID
3. Install: LEVEL” on page 3-21.
• Brake pads
• Brake pad spring
• Brake pad pin
• Brake pad clips
• Front brake caliper
• Brake hose guide
Brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)
T.
R.
Brake hose holder bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE® 7. Check:
• Brake lever operation
Refer to “REPLACING THE FRONT BRAKE Soft or spongy feeling → Bleed the brake sys-
PADS” on page 4-41. tem.
4. Fill: Refer to “BLEEDING THE HYDRAULIC
• Brake master cylinder reservoir BRAKE SYSTEM” on page 3-24.
EAS22490
mended brake fluid) REMOVING THE FRONT BRAKE MASTER
CYLINDER
Recommended fluid
DOT 4 NOTE:
Before removing the front brake master cylinder,
EWA13090
drain the brake fluid from the entire brake sys-
WARNING
tem.
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to 1. Remove:
deteriorate, causing leakage and poor • Front brake hose union bolt “1”
brake performance. • Copper washers “2”
• Refill with the same type of brake fluid that • Front brake hose “3”
is already in the system. Mixing brake fluids NOTE:
may result in a harmful chemical reaction, To collect any remaining brake fluid, place a
leading to poor brake performance. container under the master cylinder and the end
of the brake hose.
4-44
FRONT BRAKE
Recommended fluid
DOT 4
1 EAS22530
INSTALLING THE FRONT BRAKE MASTER

2 CYLINDER
3 1. Install:
• Front brake master cylinder “1”
• Front brake master cylinder holder “2”
EAS22500 Front brake master cylinder hold-

CHECKING THE FRONT BRAKE MASTER er bolt
T.
R.
CYLINDER 10 Nm (1.0 m·kg, 7.2 ft·lb)
1. Check:
• Brake master cylinder “1” NOTE:
Damage/scratches/wear → Replace. • Align the end of the brake master cylinder hold-
• Brake fluid delivery passages er with the punch mark “a” on the handlebar.
(brake master cylinder body) • First, tighten the rear bolt, then the front bolt.
Obstruction → Blow out with compressed air.
a
2
1
2. Check: 2. Install:
• Brake master cylinder kit • Copper washers New
Damage/scratches/wear → Replace. • Front brake hose “1”
3. Check: • Front brake hose union bolt “2”
• Brake master cylinder reservoir
Cracks/damage → Replace. Front brake hose union bolt
• Brake master cylinder reservoir diaphragm 30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
Damage/wear → Replace. EWA1D77008
4. Check: WARNING
• Brake hose Proper brake hose routing is essential to in-
Cracks/damage/wear → Replace. sure safe vehicle operation. Refer to “CABLE
EAS22520 ROUTING (for XV19S(C)/ XV19M(C)/
ASSEMBLING THE FRONT BRAKE MASTER XV19CTS(C)/ XV19CTM(C))” on page 2-51
CYLINDER and “CABLE ROUTING (for XV19CS(C)/
EWA13520
WARNING
• Before installation, all internal brake com- NOTE:
ponents should be cleaned and lubricated • Install the brake hose at a right angle to the
with clean or new brake fluid. front brake master cylinder as shown in the il-
• Never use solvents on internal brake com- lustration.
ponents. • While holding the brake hose, tighten the union
bolt.
4-45
FRONT BRAKE
• Turn the handlebar to the left and right to make ECA13540
sure the brake hose does not touch other parts CAUTION:
(e.g., wire harness, cables, leads). Correct if Brake fluid may damage painted surfaces
necessary. and plastic parts. Therefore, always clean up
A 4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
2 BRAKE SYSTEM” on page 3-24.
1 5. Check:
• Brake fluid level
10–30˚ Below the minimum level mark “a” → Add the
Refer to “CHECKING THE BRAKE FLUID
B LEVEL” on page 3-21.
2
1
15–35˚

XV19CTM(C) 6. Check:
B. For XV19CS(C)/ XV19C(C) • Brake lever operation
Soft or spongy feeling → Bleed the brake sys-
3. Fill:
tem.
• Brake master cylinder reservoir
mended brake fluid)
Recommended fluid
DOT 4
EWA13540
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
is already in the system. Mixing brake fluids
may result in a harmful chemical reaction,
not enter the brake master cylinder reser-
voir. Water will significantly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
4-46
REAR BRAKE
EAS22550
REAR BRAKE
Removing the rear brake pads
6 Nm (0.6 m • kg, 4.3 ft • Ib) 4

T.
R.
2
S
1
27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.

1 Rear brake caliper bolt 2
3 Rear brake pad 2
dure.
4-47
REAR BRAKE
Removing the rear brake master cylinder

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3 1
4 2
12
10
LS
11
New
LT
15 13
14 16 LT
48 Nm (4.8 m • kg, 35 ft • Ib)
T.
R.
9 6
23 Nm (2.3 m • kg, 17 ft • Ib) 7 8 New 16 Nm (1.6 m • kg, 11 ft • Ib)

T.
R.
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.

Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir hose 1
6 Rear brake master cylinder cover 1
7 Rear brake hose union bolt 1
8 Copper washer 2
9 Rear brake hose 1
10 Rear brake light switch 1
11 Right rider footrest assembly 1 XV19CTM(C)
12 Right rider footrest assembly 1 For XV19CS(C)/ XV19C(C)
13 Brake rod 1
14 Locknut 1
15 Brake master cylinder bracket 1
4-48
REAR BRAKE
Removing the rear brake master cylinder

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3 1
4 2
12
10
LS
11
New
LT
15 13
14 16 LT
48 Nm (4.8 m • kg, 35 ft • Ib)
T.
R.
9 6
23 Nm (2.3 m • kg, 17 ft • Ib) 7 8 New 16 Nm (1.6 m • kg, 11 ft • Ib)

T.
R.
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.

16 Brake master cylinder 1
dure.
4-49
REAR BRAKE
Disassembling the rear brake master cylinder
1
2 New
4 New
3 New
5
6
S

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
cedure.
4-50
REAR BRAKE
Removing the rear brake caliper
4 3
4 2 New
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
1
R.
27 Nm (2.7 m • kg, 19 ft • Ib)

T.
R.

Drain.
1 Rear brake hose union bolt 1
2 Copper washer 2
3 Rear brake hose 1
4 Rear brake caliper bolt 2
dure.
4-51
REAR BRAKE
Disassembling the rear brake caliper
New 2
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
BF

1 Brake caliper piston 1
2 Brake caliper piston dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
cedure.
4-52
REAR BRAKE
EAS22560
INTRODUCTION Brake disc thickness limit

EWA14100
5.5 mm (0.22 in)
WARNING
Disc brake components rarely require disas- 5. Adjust:
sembly. Therefore, always follow these pre- • Brake disc deflection
ventive measures: Refer to “CHECKING THE FRONT BRAKE
• Never disassemble brake components un- DISCS” on page 4-40.
less absolutely necessary.
• If any connection on the hydraulic brake Brake disc bolt
system is disconnected, the entire brake 18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
system must be disassembled, drained, LOCTITE®
cleaned, properly filled, and bled after reas-
sembly. 6. Install:
• Never use solvents on internal brake com- • Rear wheel
ponents. Refer to “REAR WHEEL” on page 4-27.
• Use only clean or new brake fluid for clean- EAS22580
ing brake components. REPLACING THE REAR BRAKE PADS

• Brake fluid may damage painted surfaces NOTE:
and plastic parts. Therefore, always clean When replacing the brake pads, it is not neces-
up any spilt brake fluid immediately. sary to disconnect the brake hose or disassem-
• Avoid brake fluid coming into contact with ble the brake caliper.
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING 1. Measure:
THE EYES: • Brake pad wear limit “a”
• Flush with water for 15 minutes and get im- Out of specification → Replace the brake
mediate medical attention. pads as a set.
Brake pad lining thickness (in-

EAS22570
CHECKING THE REAR BRAKE DISC ner)

5.8 mm (0.23 in)
1. Remove:
Limit
• Rear wheel
0.8 mm (0.03 in)
Refer to “REAR WHEEL” on page 4-27. Brake pad lining thickness (out-
2. Check: er)
• Brake disc 5.8 mm (0.23 in)
Damage/galling → Replace. Limit
3. Measure: 0.8 mm (0.03 in)
• Brake disc deflection
Out of specification → Correct the brake disc
deflection or replace the brake disc.
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-40. a
Brake disc deflection limit
0.15 mm (0.0059 in)
4. Measure:
• Brake disc thickness
Measure the brake disc thickness at a few dif-
2. Install:
ferent locations.
• Brake pads
Out of specification → Replace.
• Brake pad springs
Refer to “CHECKING THE FRONT BRAKE
DISCS” on page 4-40.
4-53
REAR BRAKE
NOTE: Refer to “BLEEDING THE HYDRAULIC

Always install new brake pads and brake pad BRAKE SYSTEM” on page 3-24.
springs as a set. EAS22590
REMOVING THE REAR BRAKE CALIPER

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose “1” tightly to the NOTE:
bleed screw “2”. Put the other end of the hose Before disassembling the brake caliper, drain
into an open container. the brake fluid from the entire brake system.
b. Loosen the bleed screw and push the brake
1. Remove:
caliper piston into the brake caliper with your
• Rear brake hose union bolt “1”
finger.
2 • Rear brake hose “3”
NOTE:
Put the end of the brake hose into a container
1 and pump out the brake fluid carefully.
c. Tighten the bleed screw.
Bleed screw (rear brake caliper)

6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
2
R.
1 3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22600
3. Install:
DISASSEMBLING THE REAR BRAKE
• Brake caliper
CALIPER
Rear brake caliper bolt 1. Remove:
27 Nm (2.7 m·kg, 19 ft·lb) • Brake caliper piston
T.
R.
• Brake caliper piston seal

4. Check: • Brake caliper piston dust seal
• Brake fluid level ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Below the minimum level mark “a” → Add the a. Blow compressed air into the brake hose joint
recommended brake fluid to the proper level. opening “a” to force out the piston from the
Refer to “CHECKING THE BRAKE FLUID brake caliper.
EWA13550
LEVEL” on page 3-21. WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
• Never try to pry out the brake caliper pis-
ton.
5. Check:
• Brake pedal operation
tem.
4-54
REAR BRAKE
a 2
b. Remove the brake caliper piston seal and EAS22650
dust seal. ASSEMBLING THE REAR BRAKE CALIPER

EWA1D77006
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
WARNING
EAS22640
CHECKING THE REAR BRAKE CALIPER • Before installation, all internal brake com-
ponents should be cleaned and lubricated
Recommended brake component replace- with clean or new brake fluid.
ment schedule • Never use solvents on internal brake com-
Brake pads If necessary ponents as they will cause the piston seal
Piston seal Every two years and dust seal to swell and distort.
• Whenever a brake caliper is disassembled,
Dust seal Every two years replace the brake caliper piston seal and
Brake hoses Every four years dust seal.
Every two years and
Brake fluid whenever the brake Recommended fluid
is disassembled DOT 4
1. Check: EAS22670
• Brake caliper piston “1” INSTALLING THE REAR BRAKE CALIPER

Rust/scratches/wear → Replace the brake 1. Install:
caliper piston. • Rear brake caliper “1”
• Brake caliper cylinder “2” (temporarily)
Scratches/wear → Replace the brake caliper • Copper washers New
assembly. • Rear brake hose “2”
• Brake caliper body “3” • Rear brake hose union bolt “3”
Cracks/damage → Replace the brake caliper
assembly. Rear brake hose union bolt
• Brake fluid delivery passages 30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
(brake caliper body)

EWA1D77008
EWA1D77005
WARNING
WARNING Proper brake hose routing is essential to in-
Whenever a brake caliper is disassembled, sure safe vehicle operation. Refer to “CABLE
replace the brake caliper piston seal and ROUTING (for XV19S(C)/ XV19M(C)/
dust seal. XV19CTS(C)/ XV19CTM(C))” on page 2-51
ECA14170
CAUTION:
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
caliper.
4-55
REAR BRAKE
5. Bleed:
• Brake system
b
6. Check:
• Brake fluid level
1
Refer to “CHECKING THE BRAKE FLUID
3 a 2 LEVEL” on page 3-21.
2. Remove:
• Rear brake caliper
3. Install:
• Brake pads
• Brake pad springs
• Rear brake caliper bolts
• Rear brake caliper a
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-53.
Rear brake caliper bolt 7. Check:

27 Nm (2.7 m·kg, 19 ft·lb) • Brake pedal operation
T.
R.

4. Fill:
tem.
• Brake fluid reservoir
mended brake fluid)
EAS22700
Recommended fluid REMOVING THE REAR BRAKE MASTER

DOT 4 CYLINDER
EWA13090
NOTE:
WARNING Before removing the rear brake master cylinder,
• Use only the designated brake fluid. Other drain the brake fluid from the entire brake sys-
brake fluids may cause the rubber seals to tem.
deteriorate, causing leakage and poor 1. Remove:
brake performance. • Rear brake hose union bolt “1”
• Refill with the same type of brake fluid that • Copper washers “2”
is already in the system. Mixing brake fluids • Rear brake hose “3”
may result in a harmful chemical reaction, NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
not enter the brake fluid reservoir. Water
of the brake hose.
the brake fluid and could cause vapor lock.
ECA13540
CAUTION:
Brake fluid may damage painted surfaces
3 2
1
4-56
REAR BRAKE
EAS22720 EC1D71009
CHECKING THE REAR BRAKE MASTER CAUTION:

CYLINDER When installing the brake hose onto the
1. Check: brake master cylinder, make sure the brake
• Brake master cylinder pipe touches the projection “a” on the brake
Damage/scratches/wear → Replace. caliper bracket as shown.
• Brake fluid delivery passages
(brake master cylinder body)
a
2. Check:
• Brake master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Brake fluid reservoir
• Brake fluid reservoir diaphragm 2 1 New
3
4. Check: 2. Fill:
• Brake hoses • Brake fluid reservoir
Cracks/damage/wear → Replace. (with the specified amount of the recom-
mended brake fluid)
EAS22730
ASSEMBLING THE REAR BRAKE MASTER Recommended fluid

CYLINDER DOT 4
EWA13520
WARNING EWA13090
• Before installation, all internal brake com- WARNING

ponents should be cleaned and lubricated • Use only the designated brake fluid. Other
with clean or new brake fluid. brake fluids may cause the rubber seals to
• Never use solvents on internal brake com- deteriorate, causing leakage and poor
ponents. brake performance.
Recommended fluid is already in the system. Mixing brake fluids
DOT 4 may result in a harmful chemical reaction,
EAS22740 • When refilling, be careful that water does
INSTALLING THE REAR BRAKE MASTER not enter the brake fluid reservoir. Water
CYLINDER will significantly lower the boiling point of
1. Install: the brake fluid and could cause vapor lock.
• Copper washers “1” New ECA13540
• Rear brake hose “2” CAUTION:

• Rear brake hose union bolt “3” Brake fluid may damage painted surfaces
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
3. Bleed:
EWA1D77008
• Brake system
WARNING
Proper brake hose routing is essential to in- BRAKE SYSTEM” on page 3-24.
sure safe vehicle operation. Refer to “CABLE 4. Check:
ROUTING (for XV19S(C)/ XV19M(C)/ • Brake fluid level
XV19CTS(C)/ XV19CTM(C))” on page 2-51 Below the minimum level mark “a” → Add the
and “CABLE ROUTING (for XV19CS(C)/ recommended brake fluid to the proper level.
XV19C(C))” on page 2-67. Refer to “CHECKING THE BRAKE FLUID
4-57
REAR BRAKE
5. Check:
• Brake pedal operation
tem.
6. Adjust:
• Brake pedal position
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-21.
7. Adjust:
• Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-23.
4-58
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
28 Nm (2.8 m • kg, 20 ft • Ib) 1

T.
R.
1 5
LS
13 2 6
2 7
16 8 10
17
4
3 LS
14
7 9
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
11 19
15 14
LT
LT
9
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
12
50 Nm (5.0 m • kg, 36 ft • Ib)
T.
R.
18
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

T.
R.

Headlight body 4-1.
1 Rearview mirror 2
2 Plastic clamp 2
3 Front brake light switch connector 2 Disconnect.
5 Front brake master cylinder assembly 1
6 Throttle cable holder 1
7 Right handlebar switch 1
8 Throttle cable 2
9 Grip end 2
10 Throttle grip 1
11 Clutch switch coupler 1 Disconnect.
12 Clutch master cylinder holder 1
13 Clutch master cylinder assembly 1
14 Left handlebar switch 1
4-59
HANDLEBAR
Removing the handlebar (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
28 Nm (2.8 m • kg, 20 ft • Ib) 1

T.
R.
1 5
LS
13 2 6
2 7
16 8 10
17
4
3 LS
14
7 9
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
11 19
15 14
LT
LT
9
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
12
50 Nm (5.0 m • kg, 36 ft • Ib)
T.
R.
18
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

T.
R.

15 Handlebar grip 1
16 Upper handlebar holder 1
17 Handlebar 1
18 Hose guide 1
19 Lower handlebar holder 1
dure.
4-60
HANDLEBAR
Removing the handlebar (for XV19CS(C)/ XV19C(C))
28 Nm (2.8 m • kg, 20 ft • Ib) 3
T.
R.
6 LS
3
19 7
14 11 10
8 9
20
5 4 LS
13 8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
21
T.
R.
15 LT 21
10 16 23 Nm (2.3 m • kg, 17 ft • Ib)
12
T.
R.
15
17 18
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
LT
2 18
LT
40 Nm (4.0 m • kg, 29 ft • Ib)

T.
R.

Headlight bracket 4-1.
3 Rearview mirror 2
4 Front brake light switch connector 2 Disconnect.
6 Front brake master cylinder assembly 1
7 Throttle cable holder 1
8 Right handlebar switch 1
9 Throttle cable 2
10 Grip end 2
11 Throttle grip 1
14 Clutch master cylinder assembly 1
15 Left handlebar switch 1
4-61
HANDLEBAR
Removing the handlebar (for XV19CS(C)/ XV19C(C))
28 Nm (2.8 m • kg, 20 ft • Ib) 3
T.
R.
6 LS
3
19 7
14 11 10
8 9
20
5 4 LS
13 8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
21
T.
R.
15 LT 21
10 16 23 Nm (2.3 m • kg, 17 ft • Ib)
12
T.
R.
15
17 18
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
LT
2 18
LT
40 Nm (4.0 m • kg, 29 ft • Ib)

T.
R.

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
dure.
4-62
HANDLEBAR
EAS22860
REMOVING THE HANDLEBAR

2 1
EWA13120
WARNING
2. Remove:
• Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar 3. Pass the left and right handlebar switch leads
and the left handlebar grip, and gradually push through the handlebar.
the grip off the handlebar. 4. Install:
• Handlebar “1”
• Upper handlebar holder “2”
Upper handlebar holder bolt

28 Nm (2.8 m·kg, 20 ft·lb)
T.
R.
ECA14250
CAUTION:
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
EAS22880
• Turn the handlebar all the way to the left
CHECKING THE HANDLEBAR and right. If there is any contact with the
1. Check: fuel tank, adjust the handlebar position.
• Handlebar
NOTE:
Bends/cracks/damage → Replace.
EWA13690 Align the match marks “a” on the handlebar with
WARNING the upper surface of the lower handlebar hold-
Do not attempt to straighten a bent handle- ers.
bar as this may dangerously weaken it.
EAS22930 2
INSTALLING THE HANDLEBAR
EWA13120
WARNING
no danger of it falling over. a
2. Connect: 1
• Throttle cable (decelerator cable) “1” 5. Install:
(to the right handlebar switch “2”) • Handlebar grip
NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Rotate the right handlebar switch and screw it a. Apply a thin coat of rubber adhesive onto the
onto the end of the throttle cable. left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
4-63
HANDLEBAR
EWA13700
• There should be 1–3 mm (0.04–0.12 in) of
WARNING clearance “c” between the throttle grip and the
Do not touch the handlebar grip until the rub- grip end.
ber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install: b
• Left handlebar switch “1”
NOTE:
Align the projection “a” on the left handlebar
switch with the hole “b” in the handlebar. a
1
b
c 2
1
a
7. Install:
• Clutch master cylinder “1”
• Clutch master cylinder holder “2”
9. Install:
Clutch master cylinder holder • Front brake master cylinder “1”
bolt • Front brake master cylinder holder “2”
T.
R.
10 Nm (1.0 m·kg, 7.2 ft·lb)

Front brake master cylinder hold-
er bolt
T.
NOTE:
R.
10 Nm (1.0 m·kg, 7.2 ft·lb)

• Align the end of the clutch master cylinder
holder with the punch mark “a” on the handle- NOTE:
bar.
• Align the end of the front brake master cylinder
• First tighten the rear bolt, then the front bolt.
holder with the punch mark “a” on the handle-
bar.
1 • First tighten the rear bolt, then the front bolt.
a
2
8. Install: 2
• Throttle grip a
• Throttle cables
10.Adjust:
• Right handlebar switch “1”
• Throttle cable free play
• Grip end “2”
Refer to “ADJUSTING THE THROTTLE CA-
NOTE: BLE FREE PLAY” on page 3-8.
• Align the projection “a” on the right handlebar
switch with the hole “b” in the handlebar.
4-64
HANDLEBAR
Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)
4-65
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
115 Nm (11.5 m • kg, 85 ft • lb)

T.
R.
19 Nm (1.9 m • kg, 13 ft • Ib)

T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib) 7
T.
R.
LT 9
4
8
1
2
11 10
5
LT
LT
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
2
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

the front fork legs.
Windshield bracket (left and right) For XV19CTS(C)/ XV19CTM(C)
Lower handlebar holder Refer to “HANDLEBAR” on page 4-59.
Front wheel Refer to “FRONT WHEEL” on page 4-18.
1 Upper bracket cover 1
2 Upper bracket pinch bolt 4 Loosen.
3 Cap bolt 1 Loosen.
4 Steering stem nut 1
5 Upper bracket 1
6 Upper front fork cover 1
7 Upper front fork cover spacer 1
8 Upper front fork cover washer 1
9 Lower front fork cover nut 2
10 Lower bracket pinch bolt 2 Loosen.
11 Lower front fork cover 1
4-66
FRONT FORK
Removing the front fork legs (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
T.
115 Nm (11.5 m • kg, 85 ft • lb)
R.
19 Nm (1.9 m • kg, 13 ft • Ib)

T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib) 7
T.
R.
LT 9
4
8
1
2
11 10
5
LT
LT
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
2
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

12 Front fork leg 1
dure.
4-67
FRONT FORK
Removing the front fork legs (for XV19CS(C)/ XV19C(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
19 Nm (1.9 m • kg, 13 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib) 1
T.
R.
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
1
2 3
2 3 1
1
3
4 3
4
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
19 Nm (1.9 m • kg, 13 ft • Ib)
T.
R.

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 pinch bolt 4 Loosen.
4 Front fork leg 2
dure.
4-68
FRONT FORK
Disassembling the front fork legs
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
2
New 3
4
7 New
13
8 New
5
14 New
6 15
16 New
17 New
11 20
18
19
12
10 New
9
LT
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.

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 rod bolt 1
10 Copper washer 1
11 Damper rod 1
12 Rebound spring 1
13 Inner tube 1
14 Oil seal 1
15 Washer 1
16 Outer tube bushing 1
4-69
FRONT FORK
Disassembling the front fork legs
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
2
New 3
4
7 New
13
8 New
5
14 New
6 15
16 New
17 New
11 20
18
19
12
10 New
9
LT
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.

17 Inner tube bushing 1
18 Spring 1
19 Oil flow stopper 1
20 Outer tube 1
cedure.
4-70
FRONT FORK
EAS22960
REMOVING THE FRONT FORK LEGS

front fork legs.
EWA13120
WARNING
NOTE:
Place the vehicle on a suitable stand so that the 3. Remove:
front wheel is elevated. • Damper rod bolt “1”
• Copper washer
2. Loosen:
NOTE:
• Lower bracket pinch bolts
EW1D71007 While holding the damper rod with the damper
WARNING rod holder “2” and T-handle “3”, loosen the
Before loosening the lower bracket pinch damper rod bolt.
bolts, support the front fork leg.
Damper rod holder
EAS22980 90890-01460
DISASSEMBLING THE FRONT FORK LEGS T-handle
The following procedure applies to both of the 90890-01326
front fork legs. T-handle 3/8" drive 60 cm long
1. Drain: YM-01326
• Fork oil
NOTE:
Stroke the outer tube several times while drain-
ing the fork oil.
4. Remove:
• Inner tube
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the front fork leg horizontally.
2. Remove: b. Securely clamp the brake caliper bracket in a
• Dust seal “1” vise with soft jaws.
• Oil seal clip “2” c. Separate the inner tube from the outer tube
(with a flathead screwdriver) by pulling the inner tube forcefully but careful-
ECA14180 ly.
CAUTION: ECA14190
CAUTION:
Do not scratch the inner tube.
• Excessive force will damage the oil seal
and bushing. A damaged oil seal or bush-
ing must be replaced.
• Avoid bottoming the inner tube into the out-
er tube during the above procedure, as the
oil flow stopper will be damaged.
4-71
FRONT FORK
Obstruction → Blow out all of the oil passag-

es with compressed air.
• Oil flow stopper
Damage → Replace.
ECA14200
CAUTION:
• The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • When disassembling and assembling the
EAS23010
front fork leg, do not allow any foreign ma-
CHECKING THE FRONT FORK LEGS terial to enter the front fork.
The following procedure applies to both of the 4. Check:
front fork legs. • Cap bolt O-ring
1. Check: Damage/wear → Replace.
• Inner tube
• Outer tube EAS23020
ASSEMBLING THE FRONT FORK LEGS

Bends/damage/scratches → Replace.
EWA13650 The following procedure applies to both of the
WARNING front fork legs.
EWA13660
Do not attempt to straighten a bent inner WARNING
tube as this may dangerously weaken it.
• Make sure the oil levels in both front fork
2. Measure: legs are equal.
• Spring free length “a” • Uneven oil levels can result in poor han-
Out of specification → Replace. dling and a loss of stability.
Fork spring free length NOTE:
XV19S(C)/ XV19M(C)/ • When assembling the front fork leg, be sure to
XV19CTS(C)/ XV19CTM(C): replace the following parts:
273.9 mm (10.78 in) –Inner tube bushing
XV19CS(C)/ XV19C(C): –Outer tube bushing
407.0 mm (16.02 in)
–Oil seal
Limit
XV19S(C)/ XV19M(C)/ –Dust seal
XV19CTS(C)/ XV19CTM(C): • Before assembling the front fork leg, make
268.4 mm (10.57 in) sure all of the components are clean.
XV19CS(C)/ XV19C(C): 1. Install:
398.9 mm (15.70 in) • Inner tube bushing “1”
• Damper rod “2”
• Rebound spring
• Spring “3”
• Oil flow stopper “4”
EC1D71012
CAUTION:
Allow the damper rod to slide slowly down
the inner tube “5” until it protrudes from the
bottom of the inner tube. Be careful not to
damage the inner tube.
3. Check:
• Damper rod
4-72
FRONT FORK
• Washer
(with the fork seal driver “2”)
3 Fork seal driver

4 90890-01442
Adjustable fork seal driver (36–46
5
1 mm)
YM-01442
2
2. Lubricate:
• Inner tube’s outer surface
Recommended oil
Yamaha fork oil 10WT
3. Install:
• Inner tube
(in the outer tube)
4. Install: 7. Install:
• Oil seal “1”
• Copper washer New (with the fork seal driver “2”)
• Damper rod bolt ECA14220
5. Tighten: CAUTION:
• Damper rod bolt “1” Make sure the numbered side of the oil seal
faces up.
Damper rod bolt
40 Nm (4.0 m·kg, 29 ft·lb) NOTE:
T.
R.
LOCTITE® • Before installing the oil seal, lubricate its lips

with lithium-soap-based grease.
NOTE: • Lubricate the outer surface of the inner tube
While holding the damper rod assembly with the with fork oil.
damper rod holder “2” and T-handle “3”, tighten • Before installing the oil seal, cover the top of
the damper rod bolt. the front fork leg with a plastic bag to protect
the oil seal during installation.
Damper rod holder
90890-01460
T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
6. Install:
• Outer tube bushing “1”
4-73
FRONT FORK
Quantity
XV19S(C)/ XV19M(C)/
571.0 cm³ (19.31 US oz) (20.10
Imp.oz)
2 XV19CS(C)/ XV19C(C):
755.0 cm³ (25.53 US oz) (26.58
1 Imp.oz)
Recommended oil
Yamaha fork oil 10WT
8. Install:
• Oil seal clip “1” 11.Measure:
• Front fork leg oil level “a”
NOTE:
(from the top of the inner tube, with the outer
Adjust the oil seal clip so that it fits into the outer tube fully compressed and without the fork
tube’s groove. spring)
Out of specification → Correct.
Level
XV19S(C)/ XV19M(C)/
124.0 mm (4.88 in)
117.0 mm (4.61 in)
NOTE:
• While filling the front fork leg, keep it upright.
9. Install: • After filling, slowly pump the front fork leg up
• Dust seal “1” and down to distribute the fork oil.
(with the fork seal driver weight “2”)
Fork seal driver

90890-01442
Adjustable fork seal driver (36–46
mm)
YM-01442
12.Install:
• Spring “1”
• Spring seat “2”
• Spacer
• Cap bolt
10.Fill: (with O-ring)
• Front fork leg NOTE:
(with the specified amount of the recom- • Install the spring with the smaller pitch facing
mended fork oil) up.
• Before installing the cap bolt, lubricate its O-
ring with grease.
• Temporarily tighten the cap bolt.
4-74
FRONT FORK
NOTE:
Align the groove “a” in the upper front fork cover
“1” with the lower front fork cover nut “2”.
2 a
1 1
EAS23050
INSTALLING THE FRONT FORK LEGS (for 2

XV19CTM(C))
The following procedure applies to both of the 6. Tighten:
front fork legs. • Steering stem nut
1. Install:
• Lower front fork cover “1” Steering stem nut
115 Nm (11.5 m·kg, 85 ft·lb)
T.
• Front fork leg “2”
R.
• Upper bracket “3” • Cap bolt
Temporarily tighten the lower bracket pinch
bolts and steering stem nut. Cap bolt
NOTE: 23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
Make sure the inner tube end is flush with the top
of the upper bracket. • Upper bracket pinch bolts
Upper bracket pinch bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
3
R.
LOCTITE®
2 NOTE:
1 Tighten the upper bracket pinch bolts to specifi-
cation twice. Tighten the upper and lower bolts
alternately, starting with the upper bolts.
• Upper bracket cover bolts
2. Tighten: Upper bracket cover bolt
• Lower bracket pinch bolts 19 Nm (1.9 m·kg, 13 ft·lb)
T.
R.
LOCTITE®
Lower bracket pinch bolt
23 Nm (2.3 m·kg, 17 ft·lb) • Upper bracket cover bolts
T.
R.
3. Remove: Upper bracket cover bolt

• Upper bracket 16 Nm (1.6 m·kg, 11 ft·lb)
T.
R.
4. Tighten: LOCTITE®
• Lower front fork cover nuts
EWA13680
Lower front fork cover nut WARNING

7 Nm (0.7 m·kg, 5.1 ft·lb) Make sure the brake hoses are routed prop-
T.
R.
erly.
5. Install:
• Upper front fork cover “1”
• Upper bracket
4-75
FRONT FORK
EAS1D77008
INSTALLING THE FRONT FORK LEGS (for

front fork legs.
1. Install:
• Front fork leg “1”
Temporarily tighten the lower bracket pinch
bolts and steering stem bolt.
NOTE:
Make sure the inner tube end is flush with the top
of the upper bracket.
2. Tighten:
• Lower bracket pinch bolts
Lower bracket pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
3. Tighten:
• Cap bolt
Cap bolt
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
• Upper bracket pinch bolts
Upper bracket pinch bolt

19 Nm (1.9 m·kg, 13 ft·lb)
T.
R.
NOTE:
Tighten the upper bracket pinch bolts to specifi-
cation twice. Tighten the upper and lower bolts
alternately, starting with the upper bolts.
EWA13680
WARNING
Make sure the brake hoses are routed prop-
erly.
4-76
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
1st 52 Nm (5.2 m • kg, 37 ft • lb)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)
R.
R.
4
LS
LS 5
LT 6
7
1 9
10
13
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
13
11
3 2
LT
12 LS
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

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 and throttle cable guide 1
3 Front brake hose joint 1
4 Lock washer 1
5 Upper ring nut 1
6 Rubber washer 1
7 Lower ring nut 1
8 Lower bracket 1
9 Upper bearing cover 1
10 Upper bearing 1
11 Lower bearing 1
12 Dust seal 1
4-77
STEERING HEAD
Removing the lower bracket (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))

1st 52 Nm (5.2 m • kg, 37 ft • lb)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)
R.
R.
4
LS
LS 5
LT 6
7
1 9
10
13
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
13
11
3 2
LT
12 LS
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

13 Bearing outer race 2
dure.
4-78
STEERING HEAD
Removing the lower bracket (for XV19CS(C)/ XV19C(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
165 Nm (16.5 m • kg, 120 ft • lb) 11
T.
R.
LS
8
13
10 Nm (1.0 m • kg, 7.2 ft • Ib) 12
T.
R.
10
1st 52 Nm (5.2 m • kg, 37 ft • lb)
T.
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)

R.
9
LS
16 Nm (1.6 m kg, 11 ft Ib)
• •
14
LS
T.
15
R.
7 16
17
19
20
7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 23
T.
R.
5 18
LT
4
23
2 LT 21
3
LS
1 7 22
LT 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
R.
R.

Lower handlebar holders Refer to “HANDLEBAR” on page 4-59.
Front fork legs Refer to “FRONT FORK” on page 4-66.
1 Plate 1
3 Front brake hose joint 1
4 Front brake hose joint holder 1
5 Lower bracket cover 1
6 Lead guide 1
7 Front turn signal/position light 2
8 Main switch cover bracket 1
9 Cable guide 1
10 Main switch 1
11 Steering stem bolt 1
12 Washer 1
13 Upper bracket 1
14 Lock washer 1
15 Upper ring nut 1
4-79
STEERING HEAD
Removing the lower bracket (for XV19CS(C)/ XV19C(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
165 Nm (16.5 m • kg, 120 ft • lb) 11
T.
R.
LS
8
13
10 Nm (1.0 m • kg, 7.2 ft • Ib) 12
T.
R.
10
1st 52 Nm (5.2 m • kg, 37 ft • lb)
T.
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)

R.
9
LS
16 Nm (1.6 m kg, 11 ft Ib)
• •
14
LS
T.
15
R.
7 16
17
19
20
7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 23
T.
R.
5 18
LT
4
23
2 LT 21
3
LS
1 7 22
LT 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
R.
R.

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
dure.
4-80
STEERING HEAD
EAS23110
b. Remove the bearing race from the lower
REMOVING THE LOWER BRACKET
bracket with a floor chisel “2” and hammer.
EWA13120
c. Install a new dust seal and new bearing rac-
WARNING es.
ECA14270
Securely support the vehicle so that there is CAUTION:
If the bearing race is not installed properly,
2. Remove: the steering head pipe could be damaged.
• Upper ring nut
• Rubber washer NOTE:
• Lower ring nut “1” • Always replace the bearings and bearing races
• Lower bracket as a set.
EWA13730 • Whenever the steering head is disassembled,
WARNING replace the dust seal.
Securely support the lower bracket so that
there is no danger of it falling.
NOTE:
Remove the lower ring nut with the steering nut
wrench “2”.
Steering nut wrench

90890-01403
Spanner wrench
YU-33975
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23120 4. Check:
CHECKING THE STEERING HEAD • Upper bracket
1. Wash: • Lower bracket
• Bearings (along with the steering stem)
• Bearing races Bends/cracks/damage → Replace.
Recommended cleaning solvent EAS23140
Kerosene INSTALLING THE STEERING HEAD (for

2. Check: XV19TMX(C))
• Bearings 1. Lubricate:
• Bearing races • Upper bearing
Damage/pitting → Replace. • Lower bearing
3. Replace: • Bearing races
• Bearings
• Bearing races Recommended lubricant
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Lithium-soap-based grease
a. Remove the bearing races from the steering
head pipe with a long rod “1” and hammer.
4-81
STEERING HEAD
• Lower ring nut “1” • Lower ring nut “1”
• Rubber washer “2” • Rubber washer “2”
• Upper ring nut “3” • Upper ring nut “3”
• Lock washer “4” • Lock washer “4”
Refer to “CHECKING AND ADJUSTING Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-27. THE STEERING HEAD” on page 3-27.
• Front brake hose joint “1” • Upper bracket
• Front brake hose guide “2” • Steering stem bolt
NOTE: NOTE:
• Make sure that the projection “a” on the lower Temporarily tighten the steering stem bolt.
bracket contacts the side “b” of the front brake
4. Install:
hose joint “1”.
• Front fork legs
• Align the projection “c” on the front brake hose
Refer to “FRONT FORK” on page 4-66.
guide with the hole “d” in the lower bracket.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
1 • Steering stem bolt
Steering stem bolt

165 Nm (16.5 m·kg, 120 ft·lb)
T.
d c 2
R.
b a 6. Install:
• Front brake hose guide “1”
4. Install:
NOTE:
• Front fork legs
• Upper bracket Align the projection “a” on the front brake hose
Refer to “FRONT FORK” on page 4-66. guide with the hole “b” in the lower bracket.
EAS1D77009
INSTALLING THE STEERING HEAD (for b

1. Lubricate:
• Upper bearing
• Lower bearing a
• Bearing races
Lithium-soap-based grease 1
4-82
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
ET1D71001

Removing the rear shock absorber assembly and swingarm
48 Nm (4.8 m • kg, 35 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 7
T.
T.
R.
R.
LT
5 LT
LT
10
LS 7 Nm (0.7 m • kg, 5.1 ft • Ib)

3
T.
LT
R.
4
11
12
8
9
2 7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
1 3
125 Nm (12.5 m • kg, 90 ft • lb)
T.
R.
LT
48 Nm (4.8 m • kg, 35 ft • Ib)

T.
R.
8
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.

Rear wheel Refer to “REAR WHEEL” on page 4-27.
Exhaust pipes Refer to “ENGINE REMOVAL” on page 5-1.
Brake master cylinder bracket Refer to “REAR BRAKE” on page 4-47.
Loosen.
Engine mounting nut (rear lower side) Refer to “ENGINE REMOVAL” on page 5-1.
1 Horn 1 coupler 1 Disconnect.
2 Horn 1 1
3 Passenger footrest (left and right) 2 For XV19S(C)/ XV19M(C) only
NOTE:
4 O2 sensor lead guide 1 Pass the O2 sensor lead through the guide.
XV19CTM(C)
5 Rear brake hose guide 1 XV19CTM(C)
6 Rear brake hose holder 1 For XV19CS(C)/ XV19C(C)
7 Rear brake hose guide 1 For XV19CS(C)/ XV19C(C)
8 Self-locking nut/Bolt/Spacer/Washer 1/1/1/1
4-83
Removing the rear shock absorber assembly and swingarm

48 Nm (4.8 m • kg, 35 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6 7
T.
T.
R.
R.
LT
5 LT
LT
10
LS 7 Nm (0.7 m • kg, 5.1 ft • Ib)

3
T.
LT
R.
4
11
12
8
9
2 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1 3
125 Nm (12.5 m • kg, 90 ft • lb)
T.
R.
LT
48 Nm (4.8 m • kg, 35 ft • Ib)

T.
R.
8
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.

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
dure.
4-84
Removing the rear shock absorber and swingarm
LS
3
New
2
LS
1
40 Nm (4.0 m • kg, 29 ft • Ib) 2
T.
R.
LS
13
9 12 1
4
LS
12
LS
6 14 13
5 11
8 New
14 14 LS
6 9
LS
7 10 14
6
LS
8 59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
6 5 4
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
LS

1 Self-locking nut/Washer/Bolt 1/2/1
2 Oil seal/Collar/Bushing/Bearing 2/2/1/2
3 Swingarm 1
5 Connecting arm 2
6 O-ring 4
7 Spacer 1
8 Bushing 4
10 Rear shock absorber 1
11 Relay arm 1
12 Oil seal/Spacer/Bearing 2/1/1
13 Oil seal/Spacer/Bearing 2/1/2
14 Collar/Oil seal/Spacer/Bearing 2/2/1/2
dure.
4-85
EAS23180
HANDLING THE REAR SHOCK ABSORBER NOTE:

EWA13740 Place the vehicle on a suitable stand so that the
WARNING rear wheel is elevated.
This rear shock absorber contains highly 2. Loosen:
compressed nitrogen gas. Before handling • Engine mounting nut (rear lower side)
the rear shock absorber, read and make sure Refer to “ENGINE REMOVAL” on page 5-1.
you understand the following information.
NOTE:
The manufacturer cannot be held responsi-
ble for property damage or personal injury Because there is force being exerted on the en-
that may result from improper handling of gine mounting bracket (left and right rear lower
the rear shock absorber. sides), it is necessary to loosen the engine
• Do not tamper or attempt to open the rear mounting nut (rear lower side) in order to create
shock absorber. some space between the connecting arms and
• Do not subject the rear shock absorber to engine bracket before removing the rear shock
an open flame or any other source of high absorber and swingarm.
heat. High heat can cause an explosion due 3. Remove:
to excessive gas pressure. • Connecting arm bolt (frame side)
• Do not deform or damage the rear shock NOTE:
absorber in any way. Rear shock absorber
When removing the connecting arm bolt (frame
damage will result in poor damping perfor-
side), hold the swingarm so that it does not drop
mance.
down.
EAS23190 4. Measure:
DISPOSING OF A REAR SHOCK ABSORBER • Swingarm side play
1. Gas pressure must be released before dis- • Swingarm vertical movement
posing of a rear shock absorber. To release ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the gas pressure, drill a 2–3 mm (0.08–0.12 a. Measure the tightening torque of the pivot
in) hole through the rear shock absorber at a shaft nut.
point 15–20 mm (0.59–0.79 in) from its end
as shown. Pivot shaft nut
EWA13760 125 Nm (12.5 m·kg, 90 ft·lb)
T.
R.
WARNING
Wear eye protection to prevent eye damage b. Measure the swingarm side play “A” by mov-
from released gas or metal chips. ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and oil seals.
Swingarm side play (at the end of

the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement “B”

by moving the swingarm up and down.
If swingarm vertical movement is not smooth
ET1D71002
or if there is binding, check the spacers, bear-
REMOVING THE REAR SHOCK ABSORBER ings, washers, and oil seals.
ASSEMBLY AND SWINGARM
EWA13120
WARNING
4-86
EAS23360
CHECKING THE SWINGARM

1. Check:
B • Swingarm
A
Bends/cracks/damage → Replace.
2. Check:
• Pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
EWA13770
WARNING
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Do not attempt to straighten a bent pivot
EAS23240 shaft.
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 rear shock
absorber assembly.
• Spring
Damage/wear → Replace the rear shock ab-
sorber assembly. 3. Wash:
• Bushing • Pivot shaft
Damage/wear → Replace the rear shock ab- • Bushing
sorber assembly. • Washer
• Spacer • Bearings
Damage/scratches → Replace. • Collars
• Bolts Recommended cleaning solvent
Bends/damage/wear → Replace. Kerosene
EAS23260
CHECKING THE CONNECTING ARM AND 4. Check:

RELAY ARM • Washer
1. Check: • Oil seals
• Connecting arms • Bushing
• Relay arm Damage/wear → Replace.
Damage/wear → Replace. • Bearings
2. Check: Damage/pitting → Replace.
• Bearings • Collar
• Oil seals Damage/scratches → Replace.
Damage/pitting → Replace. ET1D71003
3. Check: INSTALLING THE RELAY ARM, REAR
• Bushings SHOCK ABSORBER ASSEMBLY AND
Damage/wear → Replace. CONNECTING ARMS
4. Check: 1. Lubricate:
• Spacers • Oil seals
• Collars
Damage/scratches → Replace. Recommended lubricant
4-87
2. Install: • Spacer “2”

• Bearings “1”, “2”, “3” EC1D71010
(to the relay arm) CAUTION:

• Oil seals “4”, “5” When inserting the spacer into the connect-
(to the relay arm) ing arms and the rear shock absorber, be
careful not to damage the bushings and O-
Installed depth “a” rings.
4.5 mm (0.18 in)
Installed depth “b” NOTE:
1.0 mm (0.04 in) Install the bushings so that the slits “b” in the
Installed depth “c” bushings are within the areas shown in the illus-
6.0 mm (0.24 in) tration.
Installed depth “d”
2.5 mm (0.10 in)
Installed depth “a”
4.5 mm (0.18 in)
1
a
1 1 3
3 2
4 B A
4
b b b b
5 5 a a a a
B A
4
4 4
a 2 a
c c 3
d 3 3 d 1
b
C
A. Right side 3. Connecting arm
B. Left side 4. Rear shock absorber
A. Right side
3. Lubricate:
B. Left side
• Bushings
C. 90°
• Oil seals
• O-rings 5. Install:
• Collar • Connecting arms
• Rear shock absorber assembly
Recommended lubricant (to relay arm)
Lithium-soap-based grease • Relay arm
(to the swingarm)
NOTE:
NOTE:
Apply grease only to the collar between the con-
Be sure to face the “FWD” mark “a” on the relay
necting arms and rear shock absorber.
arm “1” toward the front of the vehicle and to
4. Install: face the label “b” on the rear shock absorber “2”
• Bushings “1” downward.
(to connecting arms)
4-88
1 1 2 1
b A B
2
a a
a
6. Tighten: 2. Swingarm
• Connecting-arm-to-relay-arm nut A. Left side
B. Right side
Connecting-arm-to-relay-arm nut
59 Nm (5.9 m·kg, 43 ft·lb) 3. Install:
T.
R.
• Pivot shaft
• Rear-shock-absorber-assembly-to-relay-arm • Washer
nut • Pivot shaft nut
NOTE:
Rear-shock-absorber-assembly-
to-relay-arm nut Temporarily tighten the pivot shaft nut.
T.
R.
40 Nm (4.0 m·kg, 29 ft·lb) 4. Install:

• Connecting arm bolt (front side)
• Relay-arm-to-swingarm nut
NOTE:
Relay-arm-to-swingarm nut When installing the connecting arm bolt, hold the
59 Nm (5.9 m·kg, 43 ft·lb) swingarm so that it does not drop down.
T.
R.
EAS28780
5. Tighten:
INSTALLING THE SWINGARM • Pivot shaft nut
1. Lubricate: • Engine mounting nut (rear lower side)
• Bearings • Connecting arm nut (front side)
• Collars
• Oil seals Pivot shaft nut
125 Nm (12.5 m·kg, 90 ft·lb)
T.
• Pivot shaft
R.

Recommended lubricant side)
Lithium-soap-based grease 98 Nm (9.8 m·kg, 71 ft·lb)
Connecting arm nut (front side)
2. Install: 59 Nm (5.9 m·kg, 43 ft·lb)
• Bearings “1”
6. Adjust:
(to swingarm)
Installed depth “a” Refer to “ADJUSTING THE DRIVE BELT
1.0 mm (0.04 in) SLACK” on page 3-26.
4-89
BELT DRIVE
EAS23510
BELT DRIVE
Removing the drive belt and drive pulley
T.
R.
T.
R.
63 Nm (6.3 m • kg, 45 ft • Ib)
T.
R.
9
10
13 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(3) 6
7
8
LT
LT
LT 5
7
8 12 (3)
New 11 3
E 4 1
140 Nm (14.0 m • kg, 100 ft • lb)
T.
R.
(4)
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
(6)

Rear wheel Refer to “REAR WHEEL” on page 4-27.
Refer to “REAR SHOCK ABSORBER AS-
Rear shock absorber assembly and swingarm SEMBLY AND SWINGARM” on page 4-83.
1 Rectifier/regulator cover 1
2 Lead cover 1
3 Stator coil coupler 1 Disconnect.
4 Rectifier/regulator coupler 1 Disconnect.
5 Rectifier/regulator 1
6 Drive pulley cover 1
7 Slider 2
8 Dowel pin 2
9 Transfer gear case bracket 1
10 Drive belt 1
11 Drive pulley nut 1
12 Conical spring washer 1
4-90
BELT DRIVE
Removing the drive belt and drive pulley
T.
R.
T.
R.
63 Nm (6.3 m • kg, 45 ft • Ib)
T.
R.
9
10
13 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(3) 6
7
8
LT
LT
LT 5
7
8 12 (3)
New 11 3
E 4 1
140 Nm (14.0 m • kg, 100 ft • lb)
T.
R.
(4)
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
(6)

13 Drive pulley 1
dure.
4-91
BELT DRIVE
EAS23520
• The drive belt can not be bent smaller than
REMOVING THE DRIVE BELT AND DRIVE
127 mm (5 in) “a”.
PULLEY
• The removed drive belt can not be twisted
NOTE: inside out.
Loosen the drive pulley nut before removing the
rear wheel.
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.
3. Check:
• Drive pulley
• Rear wheel pulley
Bent teeth → Replace the drive belt and pul-
leys as a set.
EAS23540
1 INSTALLING THE DRIVE BELT AND DRIVE
PULLEY
1. Install:
EAS23530
CHECKING THE DRIVE BELT • Drive pulley “1”

1. Clean: • Conical spring washer “2”
• Drive belt • Drive pulley nut “3” New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE:
a. Wipe the drive belt with a clean cloth.
• Install the conical spring washer “2” with the
b. Put the drive belt in a mixture of mild deter-
“OUT” mark “a” facing out.
gent and water. Then, remove any dirt from
• Apply engine oil to the conical spring washer
the drive belt.
and drive pulley nut.
c. Remove the drive belt from the mixture and
rinse it off with clean water. Then, let the drive
belt thoroughly dry. 2
OUT a
3 New
2. Install:
• Drive belt
ECA14710
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CAUTION:
2. Check:
• Drive belt Install the drive belt facing the same way it
ECA14690 was removed.
CAUTION: Do not twist the drive belt when installing it.
• To protect the drive belt from damage, han-
dle it with care.
4-92
BELT DRIVE
3. Install:
• Swingarm
• Rear shock absorber
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY AND SWINGARM” on page 4-83.
• Rear wheel
Refer to “REAR WHEEL” on page 4-27.
4. Tighten:
• Drive pulley nut
Drive pulley nut

140 Nm (14.0 m·kg, 100 ft·lb)
T.
R.
NOTE:
• When tightening the drive pulley nut, press
down on the brake pedal so the drive pulley
does not move.
• Stake the drive pulley nut “1” at a cutout “a” in
the middle driven shaft.
5. Adjust:
Refer to “ADJUSTING THE DRIVE BELT
SLACK” on page 3-26.
4-93
ENGINE
ENGINE REMOVAL ........................................................................................5-1

INSTALLING THE SHIFT PEDAL ASSEMBLY......................................... 5-8
CHECKING THE OIL COOLER (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C)) .................................................................. 5-10
REMOVING THE ENGINE ...................................................................... 5-15
INSTALLING THE ENGINE..................................................................... 5-15
CAMSHAFTS.................................................................................................5-17
REMOVING THE CYLINDER HEAD COVERS ...................................... 5-24
REMOVING THE ROCKER ARMS,
PUSH RODS AND VALVE LIFTERS .....................................................5-24
REMOVING THE CAMSHAFTS..............................................................5-24
CHECKING THE CAMSHAFTS ..............................................................5-26
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-27
CHECKING THE ROCKER ARM BASES ............................................... 5-28
CHECKING THE PUSH RODS ...............................................................5-28
CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES .........5-28
CHECKING THE PUSH ROD COVER....................................................5-29
CHECKING THE DECOMPRESSION SYSTEM..................................... 5-29
CHECKING THE DECOMPRESSION CAM SPRING............................. 5-29
CHECKING THE OIL DELIVERY PIPE...................................................5-30
INSTALLING THE CAMSHAFTS ............................................................ 5-30
BLEEDING A VALVE LIFTER .................................................................5-32
INSTALLING THE VALVE LIFTERS .......................................................5-33
INSTALLING THE ROCKER ARMS AND PUSH RODS......................... 5-34
INSTALLING THE CYLINDER HEAD COVERS ..................................... 5-35
5
INSTALLING THE SHIFT PEDAL ASSEMBLY (for XV19S(C)/
XV19M(C)/ XV19CTS(C)/ XV19CTM(C)) ............................................... 5-35
CYLINDER HEADS ....................................................................................... 5-36

REMOVING THE CYLINDER HEADS ....................................................5-38
CHECKING THE CYLINDER HEADS.....................................................5-38
CHECKING THE OIL PIPE ..................................................................... 5-38
INSTALLING THE CYLINDER HEADS...................................................5-39
VALVES AND VALVE SPRINGS.................................................................. 5-41

REMOVING THE VALVES...................................................................... 5-42
CHECKING THE VALVES AND VALVE GUIDES ..................................5-42
CHECKING THE VALVE SEATS ............................................................ 5-44
CHECKING THE VALVE SPRINGS........................................................ 5-45
INSTALLING THE VALVES .................................................................... 5-46
CYLINDERS AND PISTONS.........................................................................5-48

REMOVING THE PISTON ...................................................................... 5-49
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-49
CHECKING THE PISTON RINGS........................................................... 5-50
CHECKING THE PISTON PINS..............................................................5-51
INSTALLING THE PISTONS AND CYLINDERS .................................... 5-51
CLUTCH ........................................................................................................5-53
REMOVING THE CLUTCH ..................................................................... 5-64
REMOVING THE PRIMARY DRIVE GEAR ............................................5-64
REMOVING THE LEFT BALANCER DRIVE GEAR ...............................5-64
CHECKING THE FRICTION PLATES.....................................................5-65
CHECKING THE CLUTCH PLATES .......................................................5-65
CHECKING THE CLUTCH SPRING PLATE...........................................5-65
CHECKING THE CLUTCH HOUSING ....................................................5-66
CHECKING THE CLUTCH BOSS........................................................... 5-66
CHECKING THE PRESSURE PLATE ....................................................5-66
CHECKING THE CLUTCH PUSH RODS ............................................... 5-66
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-66
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-66
CHECKING THE LEFT BALANCER GEARS..........................................5-66
INSTALLING THE LEFT BALANCER DRIVE GEAR ..............................5-67
INSTALLING THE PRIMARY DRIVE GEAR...........................................5-68
INSTALLING THE CLUTCH.................................................................... 5-69
DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-70
CHECKING THE CLUTCH MASTER CYLINDER................................... 5-70
ASSEMBLING THE CLUTCH MASTER CYLINDER ..............................5-71
INSTALLING THE CLUTCH MASTER CYLINDER.................................5-71
REMOVING THE CLUTCH RELEASE CYLINDER ................................5-72
CHECKING THE CLUTCH RELEASE CYLINDER .................................5-72
ASSEMBLING THE CLUTCH RELEASE CYLINDER............................. 5-73
INSTALLING THE CLUTCH RELEASE CYLINDER ...............................5-73
SHIFT SHAFT................................................................................................5-75
CHECKING THE SHIFT SHAFT ............................................................. 5-76
CHECKING THE STOPPER LEVER ......................................................5-76
INSTALLING THE SHIFT SHAFT ........................................................... 5-76
GENERATOR AND STARTER CLUTCH......................................................5-77

REMOVING THE GENERATOR ............................................................. 5-79
REMOVING THE STARTER CLUTCH ...................................................5-79
CHECKING THE STARTER CLUTCH ....................................................5-79
CHECKING THE TORQUE LIMITER......................................................5-80
INSTALLING THE STARTER CLUTCH .................................................. 5-80
INSTALLING THE GENERATOR............................................................ 5-80
ELECTRIC STARTER ...................................................................................5-82

CHECKING THE STARTER MOTOR .....................................................5-84
ASSEMBLING THE STARTER MOTOR................................................. 5-85
TRANSFER GEAR CASE ............................................................................. 5-86

REMOVING THE MIDDLE DRIVEN SHAFT...........................................5-91
CHECKING THE MIDDLE DRIVE........................................................... 5-91
CHECKING THE OIL STRAINER ........................................................... 5-91
CHECKING THE TRANSFER GEAR OIL PUMP.................................... 5-91
CHECKING THE OIL PIPES ................................................................... 5-92
ASSEMBLING THE TRANSFER GEAR OIL PUMP ...............................5-92
INSTALLING THE TRANSFER GEAR CASE .........................................5-92
CRANKCASE ................................................................................................5-94
DISASSEMBLING THE CRANKCASE....................................................5-97
CHECKING THE CRANKCASE ..............................................................5-97
CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-97
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE .......................... 5-97
CHECKING THE OIL STRAINERS ......................................................... 5-97
CHECKING THE ENGINE OIL PUMP DRIVEN GEAR........................... 5-97
INSTALLING THE BEARING RETAINERS............................................. 5-98
ASSEMBLING THE CRANKCASE.......................................................... 5-98
OIL PUMP....................................................................................................5-100
CHECKING THE OIL PUMP .................................................................5-103
CHECKING THE RELIEF VALVE .........................................................5-103
CHECKING THE BALL SPRING AND RELIEF VALVE SPRING .........5-103
CHECKING THE OIL STRAINER .........................................................5-104
ASSEMBLING THE OIL PUMP.............................................................5-104
INSTALLING THE OIL PUMP ...............................................................5-105
CRANKSHAFT ............................................................................................5-106
REMOVING THE CONNECTING RODS ..............................................5-107
CHECKING THE CRANKSHAFT AND CONNECTING RODS.............5-107
INSTALLING THE CONNECTING RODS.............................................5-110
INSTALLING THE CRANKSHAFT ASSEMBLY....................................5-111
TRANSMISSION..........................................................................................5-112
CHECKING THE SHIFT FORKS...........................................................5-116
CHECKING THE SHIFT DRUM ASSEMBLY........................................5-116
CHECKING THE TRANSMISSION .......................................................5-116
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ............................5-117
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ....5-117
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the muffler and exhaust pipes (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
29 Nm (2.9 m • kg, 21 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

T.
R.
5
7 LT
6
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
44 Nm (4.4 m • kg, 32 ft • Ib)
T.
R.
8 12 New S
LT
LT 1
10
9 New 2 New
4
New 15
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib) 11 LT

LT
14
T.
R.

T.
R.
T.
R.
New 12 20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.

1 Rear brake light switch 1
2 Right rider footrest assembly 1
3 EXUP valve pulley cover 1
4 EXUP cable 2 Disconnect.
5 O2 sensor coupler holder 1
6 O2 sensor coupler 1 Disconnect.
7 Muffler bracket 1
8 Muffler 1
9 Gasket 1
10 Rear exhaust pipe cover 1
11 Rear exhaust pipe 1
12 Gasket 2
13 O2 sensor 1
14 Front exhaust pipe 1
5-1
ENGINE REMOVAL
Removing the muffler and exhaust pipes (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
29 Nm (2.9 m • kg, 21 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

T.
R.
5
7 LT
6
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
44 Nm (4.4 m • kg, 32 ft • Ib)
T.
R.
8 12 New S
LT
LT 1
10
9 New 2 New
4
New 15
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib) 11 LT

LT
14
T.
R.

T.
R.
T.
R.
New 12 20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.

15 Gasket 1
dure.
5-2
ENGINE REMOVAL
Removing the muffler and exhaust pipes (for XV19CS(C)/ XV19C(C))
T.
T.
R.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
6
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
LT
LT
5
10
New 9
8
2 4 7 LS
New
24 Nm (2.4 m • kg, 17 ft • Ib) 13
T.
R.
11 New
New LS
1 12
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
44 Nm (4.4 m • kg, 32 ft • Ib)

T.
R.

Rider seat 4-1.
1 EXUP valve pulley cover 1
2 Muffler 1
3 Muffler bracket 1
4 Gasket 1
5 EXUP cable 2 Disconnect.
6 O2 sensor coupler 1 Disconnect.
7 O2 sensor 1
8 Rear exhaust pipe cover 1

9 Rear exhaust pipe 1
10 Gasket 1
11 Gasket 1
12 Front exhaust pipe 1
13 Gasket 1
dure.
5-3
ENGINE REMOVAL
Removing the cylinder-#1 ignition coils and sidestand (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
LT LT
LT
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
1
5 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4 2 9
3 10
3
LT
6
11
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
16
17
18 New
14 12
19
LT
LT
LT 15
LT
LT 8
63 Nm (6.3 m • kg, 45 ft • Ib) 48 Nm (4.8 m • kg, 35 ft • Ib) 13
T.
T.
R.
R.

T.
T.
R.
R.

Rider seat/Left side cover/Battery box/Air filter Refer to “GENERAL CHASSIS” on page
case 4-1.
Fuel tank/Sub-fuel tank Refer to “FUEL TANK” on page 6-1.
Throttle body/Intake manifold/Pressure regula- Refer to “THROTTLE BODIES” on page 6-7.
tor bracket/Rollover valve/Canister
Rear brake master cylinder bracket Refer to “REAR BRAKE” on page 4-47.
Drive pulley Refer to “BELT DRIVE” on page 4-90.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Drain.
Transfer gear oil Refer to “CHANGING THE TRANSFER
GEAR OIL” on page 3-14.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-82.
1 Cylinder-#1 ignition coil cover 1
2 Spark plug cap 2
3 Ignition coil connector 4 Disconnect.
4 Cylinder-#1 left ignition coil 1
5 Cylinder-#1 right ignition coil 1
5-4
ENGINE REMOVAL
Removing the cylinder-#1 ignition coils and sidestand (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
LT LT
LT
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
1
5 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4 2 9
3 10
3
LT
6
11
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
16
17
18 New
14 12
19
LT
LT
LT 15
LT
LT 8
63 Nm (6.3 m • kg, 45 ft • Ib) 48 Nm (4.8 m • kg, 35 ft • Ib) 13
T.
T.
R.
R.

T.
T.
R.
R.

6 Cylinder-#1 ignition coil bracket 1
Except for California
7 Horn 1 connector 2 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 Shift pedal (toe side) 1
16 Shift pedal (heel side) 1
17 Shift pedal shaft 1
18 Sidestand switch 1
19 Sidestand 1
dure.
5-5
ENGINE REMOVAL
Removing the right ignition coils and sidestand (for XV19CS(C)/ XV19C(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
LT
T.
R.
5 2
LT
1 2
4 3
3
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
LT
6
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
9
10
12
14
13
7
LT
LT
LT
15
LT
LT 8
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Rider seat/Left side cover/Battery box/Air filter Refer to “GENERAL CHASSIS” on page
case 4-1.
Throttle body/Intake manifold/Pressure regula- Refer to “THROTTLE BODIES” on page 6-7.
tor bracket/Rollover valve/Canister
Rear brake master cylinder bracket Refer to “REAR BRAKE” on page 4-47.
Drain.
page 3-11.
Drain.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-82.
1 Right ignition coil cover 1
2 Spark plug cap 2
5-6
ENGINE REMOVAL
Removing the right ignition coils and sidestand (for XV19CS(C)/ XV19C(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
LT
T.
R.
5 2
LT
1 2
4 3
3
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
LT
6
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
9
10
12
14
13
7
LT
LT
LT
15
LT
LT 8
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

6 Right ignition coil bracket 1
Except for California
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
dure.
5-7
ENGINE REMOVAL
ET1D71029
INSTALLING THE SHIFT PEDAL ASSEMBLY

1. Assemble: (for XV19S(C)/ XV19M(C)/
• Shift pedal (heel side) “1”
• Shift pedal (toe side) “2”
Shift pedal (heel side) bolt

13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
R.
NOTE:
Align the mark “a” on the pin on the toe side with
the mark “b” on the heel side.
2
1 b a

Shift pedal bolt

18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
NOTE:
Align the mark “a” on the shift pedal shaft with
the slot in the shift pedal.
3. Adjust: (for XV19CS(C)/ XV19C(C))

• Shift rod length
Refer to “ADJUSTING THE SHIFT PEDAL”
on page 3-25.
5-8
ENGINE REMOVAL
Removing the oil cooler and oil filter bracket

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
LS 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
New
5
New LS
LS
3
2
New New
New New LS
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
LS
6
1
LS 7
17 Nm (1.7 m • kg, 12 ft • Ib)
New
T.
R.
New
E
(4)
7 Nm (0.7 m • kg, 5.1 ft • Ib) 70 Nm (7.0 m • kg, 50 ft • lb)
T.
T.
R.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib) LT 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
T.
R.
R.

1 Oil filter cartridge 1
2 Oil cooler outlet hose 1
XV19CTM(C)
3 Oil cooler inlet hose 1 XV19CTM(C)
4 Oil cooler 1 XV19CTM(C)
5 Oil cooler bracket 1 XV19CTM(C)
6 Oil filter bolt 1
7 Oil filter bracket 1
dure.
5-9
ENGINE REMOVAL
ET1D71028
CHECKING THE OIL COOLER (for XV19S(C)/

1. Check:
• Oil cooler fins
Obstruction → Clean.
Apply compressed air to the rear of the oil
cooler.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead
screwdriver.
2. Check:
• Oil cooler inlet hose
• Oil cooler outlet hose
5-10
ENGINE REMOVAL
Disconnecting the leads

1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
12 3
4
7 Nm (0.7 m • kg, 5.1 ft • Ib) 13
T.
R.
5
6
15
LT
2
14 11
10 8 7
LT

T.
T.
R.
R.

Refer to “TRANSFER GEAR CASE” on
Drive pulley case 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 Throttle cable guide 1
8 Starter motor lead 1
9 Horn 2 lead 1
10 Rear brake light switch lead 1
11 Sidestand switch lead 1
12 Crankshaft position sensor coupler 1 Disconnect.
13 Crankshaft position sensor lead 1
14 Rectifier/regulator lead 1
5-11
ENGINE REMOVAL
Disconnecting the leads

1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
12 3
4
7 Nm (0.7 m • kg, 5.1 ft • Ib) 13
T.
R.
5
6
15
LT
2
14 11
10 8 7
LT

T.
T.
R.
R.

15 Speed sensor lead 1
dure.
5-12
ENGINE REMOVAL
Removing the engine

A 105 Nm (10.5 m • kg, 75 ft • lb) A 59 Nm (5.9 m • kg, 43 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
B 90 Nm (9.0 m • kg, 65 ft • lb)

R.
T.
B 66 Nm (6.6 m • kg, 48 ft • lb)
R.
66 Nm (6.6 m • kg, 48 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) 98 Nm (9.8 m • kg, 71 ft • lb)
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
R.
LT 2
19 6
8 22 2
12 E 17
1 3 5
13 20 15 18
24
23 4
E
11 21 16
25
10
18
LT
14
9
LT
7
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

13 12
T.
R.
98 Nm (9.8 m • kg, 71 ft • lb)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

T.
R.
NOTE:
Place a suitable stand under the frame and
engine.

Transfer gear case page 5-86.
1 Engine mounting bolt (right upper side) 2
2 Engine mounting bolt (left upper side) 2
3 Engine bracket bolt (right upper side) 2
4 Engine bracket (right upper side) 1
5 Engine bracket bolt (left upper side) 2
6 Engine bracket (left upper side) 1
7 Engine mounting nut (front upper side) 1
8 Engine mounting bolt (front upper side) 1
9 Engine cross-member bracket bolt 2
10 Engine cross-member bracket 1
11 Engine bracket nut (front upper side) 4
12 Engine bracket bolt (front upper side) 4
13 Engine bracket (front upper side) 2
5-13
ENGINE REMOVAL
Removing the engine

A 105 Nm (10.5 m • kg, 75 ft • lb) A 59 Nm (5.9 m • kg, 43 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
B 90 Nm (9.0 m • kg, 65 ft • lb)

R.
T.
B 66 Nm (6.6 m • kg, 48 ft • lb)
R.
66 Nm (6.6 m • kg, 48 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) 98 Nm (9.8 m • kg, 71 ft • lb)
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
R.
LT 2
19 6
8 22 2
12 E 17
1 3 5
13 20 15 18
24
23 4
E
11 21 16
25
10
18
LT
14
9
LT
7
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

13 12
T.
R.
98 Nm (9.8 m • kg, 71 ft • lb)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

T.
R.

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 side) 2
19 Engine mounting nut (front lower side) 1
20 Spacer bolt 1 Loosen.
21 Engine mounting bolt (front lower side) 1
22 Engine mounting nut (rear lower side) 1
23 Engine mounting bolt (rear lower side) 1
24 Washer 1
25 Engine 1
dure.
A: For XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C)

B: For XV19CS(C)/ XV19C(C)
5-14
ENGINE REMOVAL
ET1D71019
3. Tighten:
REMOVING THE ENGINE
• Spacer bolt “1”
1. Loosen:
• Spacer bolt Spacer bolt
NOTE: 18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
Loosen the spacer bolt with the pivot shaft
wrench “1”. NOTE:
• Tighten the spacer bolt “1” to specification with
Pivot shaft wrench a pivot shaft wrench.
90890-01485 • When tightened, the spacer bolt should be flat
Frame mount insert wrench against the engine surface.
YM-01485
Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485
3
5 4
1
EAS23720
1
INSTALLING THE ENGINE
1. Install: 7 6 14 13 14
• Spacer bolt “1”
• Engine “2” 11 9 8 LT
• Washer “3” 18 9
17
• Engine mounting bolt (rear lower side) “4” E 15
• Engine mounting nut (rear lower side) “5”
• Engine mounting bolt (front lower side) “6” 16
• Engine mounting nut (front lower side) “7” 2
• Engine brackets (rear upper side) “8”
• Engine bracket bolts (rear upper side) “9”
• Engine bracket nuts (rear upper side) “10” 8
12 10
• Engine mounting bolt (rear upper side) “11”
• Engine mounting nut (rear upper side) “12”
• Engine bracket (left upper side) “13” 4. Tighten:
• Engine mounting bolts (left upper side) “14” • Engine mounting nut (rear lower side) “5”
• Engine bracket bolts (left upper side) “15” • Engine mounting nut (front lower side) “7”
• Engine bracket (right upper side) “16” • Engine bracket nuts (rear upper side) “10”
• Engine mounting bolts (right upper side) “17” • Engine mounting nut (rear upper side) “12”
• Engine bracket bolts (right upper side) “18” • Engine mounting bolts (left upper side) “14”
NOTE: • Engine bracket bolts (left upper side) “15”
• Lubricate the engine mounting bolt (front lower • Engine mounting bolts (right upper side) “17”
side) threads and nut with engine oil. • Engine bracket bolts (right upper side) “18”
threads of the engine mounting bolts (left up-
per side).
• Do not fully tighten the bolts and nuts.
2. Remove:
• Engine mounting nut (front lower side) “7”
5-15
ENGINE REMOVAL
NOTE:
T. side) To install and route the leads, refer to “CABLE
R.
98 Nm (9.8 m·kg, 71 ft·lb) ROUTING (for XV19S(C)/ XV19M(C)/

Engine mounting nut (front lower XV19CTS(C)/ XV19CTM(C))” on page 2-51 and
side) “CABLE ROUTING (for XV19CS(C)/
XV19S(C)/ XV19M(C)/ XV19C(C))” on page 2-67.
105 Nm (10.5 m·kg, 75 ft·lb)
XV19CS(C)/ XV19C(C): 7. Install:
90 Nm (9.0 m·kg, 65 ft·lb) • Transfer gear case
Engine bracket nut (rear upper • Drive pulley case
side) Refer to “TRANSFER GEAR CASE” on page
53 Nm (5.3 m·kg, 38 ft·lb) 5-86.
Engine mounting nut (rear upper 8. Install:
side) • Drive pulley
98 Nm (9.8 m·kg, 71 ft·lb) • Transfer gear case bracket
Engine mounting bolt (left upper Refer to “BELT DRIVE” on page 4-90.
side) 9. Tighten:
66 Nm (6.6 m·kg, 48 ft·lb) • Engine bracket nuts (front upper side) “3”
LOCTITE®
• Engine cross-member bracket bolts “5”
Engine mounting bolt (right up-
per side) • Engine mounting nut (front upper side) “7”
XV19S(C)/ XV19M(C)/
Engine bracket nut (front upper
side)
59 Nm (5.9 m·kg, 43 ft·lb)
T.
R.
53 Nm (5.3 m·kg, 38 ft·lb)

Engine cross-member bracket
66 Nm (6.6 m·kg, 48 ft·lb)
bolt
30 Nm (3.0 m·kg, 22 ft·lb)
side)
LOCTITE®
53 Nm (5.3 m·kg, 38 ft·lb)
Engine mounting nut (front upper
side)
side)
98 Nm (9.8 m·kg, 71 ft·lb)
53 Nm (5.3 m·kg, 38 ft·lb)
5. Install:
• Engine brackets (front upper side) “1” 3
• Engine bracket bolts (front upper side) “2” 7
• Engine bracket nuts (front upper side) “3” 2 6
• Engine cross-member bracket “4”
• Engine cross-member bracket bolts “5” 1
5 2
• Engine mounting bolt (front upper side) “6”
4
• Engine mounting nut (front upper side) “7” 5
NOTE: 1
Do not fully tighten the bolts and nuts.
6. Install:
• Lead holder bracket
• Lead
(removed during engine removal)
5-16
CAMSHAFTS
EAS23750
CAMSHAFTS
Removing the camshaft sprocket cover
1 1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
1
2
1
(5)
2
2
(3)
9
8
New 10
5 (3)
New
7 4
LS
6
T.
R.
T.
R.
3 18 Nm (1.8 m • kg, 13 ft • Ib)

T.
R.

Air filter case 4-1.
Muffler/Exhaust pipes Refer to “ENGINE REMOVAL” on page 5-1.
1 Spark plug cap 4 Disconnect.
2 Spark plug 4
3 Shift pedal assembly 1 XV19CTM(C)
4 Damper cover 1
5 Damper 1
6 Timing mark accessing screw 1
7 Crankshaft end screw 1
8 Camshaft sprocket cover 1
9 Dowel pin 2
10 Camshaft sprocket cover gasket 1
dure.
5-17
CAMSHAFTS
Removing the cylinder head covers

10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 6 7
T.
R.
1 7 7 7 6
6
7
7
6 6
6 8
10 New
10 New
2 11
11
4 3
5
LT
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

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 cover bolt 20 l = 60 mm (2.36 in)
8 Rear cylinder head cover 1
9 Front cylinder head cover 1
10 Cylinder head cover gasket 2
11 Dowel pin 4
dure.
5-18
CAMSHAFTS
Removing the push rods and rocker arms

T
.
T.
R.
R.
24 Nm (2.4 m • kg, 17 ft • Ib)
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
T.
R.
10 8 10 10
1 11 9 11 11
E
2 8
10
11
9
E
7
7
13
E 7 12
E
4
New 3 4 E
E 4
5 3 New E
5
6
E
E E

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 blue painting
7 Rocker arm shaft 4
8 Rocker arm 1 2
9 Rocker arm 2 2
10 Locknut 4
11 Adjusting screw 4
12 Rear rocker arm base 1
13 Front rocker arm base 1
dure.
5-19
CAMSHAFTS
Removing the valve lifters

LS
LT
LT 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2 New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
5 LS
LS
New New 6 LT
LT
New
LS
1
2
E LS
7 E
New 4 1
New 3 7
LS 4 New
LS
3 New

Refer to “CYLINDERS AND PISTONS” on
Front cylinder 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
dure.
5-20
CAMSHAFTS
Removing the camshafts and right balancer
18
20
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
19 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
17 New New LS
16 New
15
M
21
7
6
5
18 4 8
9
2
E New 3 E
11
14
(7) 1
13 E
12
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

T.
T.
R.
R.

1 Camshaft driven gear 1
2 Straight key 1
3 Circlip 1
4 Washer 1
6 Washer 1
7 Rear cylinder camshaft gear 1
8 Front cylinder camshaft gear 1
9 Straight key 1
10 Right balancer driven gear 1
11 Straight key 1
12 Camshaft drive gear 1
13 Right balancer drive gear 1
14 Straight key 1
15 Oil delivery pipe 1 1
16 Camshaft cover 1
17 Camshaft cover gasket 1
5-21
CAMSHAFTS
Removing the camshafts and right balancer
18
20
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
19 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
17 New New LS
16 New
15
M
21
7
6
5
18 4 8
9
2
E New 3 E
11
14
(7) 1
13 E
12
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

T.
T.
R.
R.

18 Dowel pin 2
19 Rear cylinder camshaft 1
20 Front cylinder camshaft 1
21 Right balancer 1
dure.
5-22
CAMSHAFTS
Disassembling the camshafts
6 E
New 1 3
2 E 2
1 New
3
5
7
4
E

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
cedure.
5-23
CAMSHAFTS
ET1D71030
REMOVING THE CYLINDER HEAD COVERS

1. Remove:
• Front cylinder
• Rear cylinder “1”
NOTE:
d
Due to the small clearance between the frame c
“2” cannot be removed when the cover is in
place. Loosen the bolts, and then remove the
cover from the right side of the vehicle, making ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sure that the bolts do not scratch the rocker arms
2. Remove:
or other engine parts.
• Rocker arm bases
(with the rocker arms)
3. Remove:
2 • Valve lifters
NOTE:
Make a note of the position of each valve lifter so
that they can be installed in the correct place.
1
2
EAS23790
REMOVING THE ROCKER ARMS, PUSH

RODS AND VALVE LIFTERS
1. Align:
• TDC mark “a” on the crankshaft position sen-
sor rotor
(with the pointer “b” on the clutch cover)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise.
b. When piston #1 is at TDC on the compres-
sion stroke, align the TDC mark “a” on the
crankshaft position sensor rotor with the
pointer “b” on the clutch cover.
b a
EAS23830
REMOVING THE CAMSHAFTS

1. Loosen:
• Camshaft driven gear bolt “1”
NOTE:
c. Check the camshaft drive gear mark “c” posi- • Place a folded copper washer “2” between the
tion and camshaft driven gear mark “d” posi- teeth of the camshaft drive gear and camshaft
tion as shown. driven gear in order to lock them.
If the marks are not aligned, turn the crank- • Do not damage the teeth of the camshaft drive
shaft counterclockwise 360 degrees and re- and camshaft driven gears.
check step (b).
5-24
CAMSHAFTS
NOTE:
1 • 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
2 balancer driven gear in order to lock them.
• Do not damage the teeth of the right balancer
drive and right balancer driven gears.
2. Remove:
• Camshaft driven gear
• Straight key
NOTE:
Cover the crankcase hole with a clean rag to 3
prevent the straight key from falling into the
crankcase. 1
3. Loosen:
• Front cylinder camshaft gear bolt “1”
NOTE:
teeth of the front cylinder camshaft gear and
rear cylinder camshaft gear in order to lock
them.
• Do not damage the teeth of the front cylinder
camshaft and rear cylinder camshaft gears. 2 4
2 1
6. Remove:
• Right balancer driven gear
• Camshaft drive gear
• Right balancer drive gear
• Straight keys
NOTE:
Cover the crankcase hole with a clean rag to
4. Remove: prevent the straight keys from falling into the
• Rear cylinder camshaft gear crankcase.
• Front cylinder camshaft gear 7. Remove:
• Straight key • Oil delivery pipe 1 “1”
NOTE: • Camshaft cover “2”
Cover the crankcase hole with a clean rag to NOTE:
prevent the straight key from falling into the Loosen each bolt 1/4 of a turn at a time, in stag-
crankcase. es and in a crisscross pattern. After all of the
5. Loosen: bolts are fully loosened, remove them.
• Camshaft drive gear bolt “1”
• Right balancer driven gear bolt “2”
5-25
CAMSHAFTS
EAS23860
CHECKING THE CAMSHAFTS

1. Check:
• Cam
Blue discoloration/pitting/scratches → Re-
place the camshaft.
2. Measure:
• Cam dimensions A “a” and B “b”
Out of specification → Replace the camshaft.
Camshaft lobe dimensions

3. Measure:
Intake A
42.532–42.632 mm (1.6745– • Camshaft journal diameter (crankcase side)
1.6784 in) “a”
Limit Out of specification → Replace the camshaft.
42.432 mm (1.6705 in)
Intake B Camshaft journal diameter
35.950–36.050 mm (1.4154– (crankcase side)
1.4193 in) 24.957–24.980 mm (0.9826–
Limit 0.9835 in)
35.850 mm (1.4114 in)
Exhaust A
42.530–42.630 mm (1.6744– a
1.6783 in) (cylinder #1)
42.531–42.631 mm (1.6744–
1.6784 in) (cylinder #2) a
Limit
42.430 mm (1.6705 in) (cylinder
#1)
42.431 mm (1.6705 in) (cylinder
#2)
Exhaust B
35.950–36.050 mm (1.4154– 4. Measure:
1.4193 in) • Camshaft journal diameter (camshaft cover
Limit side) “a”
35.850 mm (1.4114 in) Out of specification → Replace the camshaft.
Camshaft journal diameter (cam-

shaft cover side)
27.957–27.980 mm (1.1007–
1.1016 in)
5-26
CAMSHAFTS
NOTE:
Calculate the clearance by subtracting the cam-
shaft journal diameter (crankcase side) from the
crankcase hole inside diameter.
a Camshaft to crankcase clearance

0.020–0.064 mm (0.0008–0.0025
a in)
8. Calculate:
5. Measure: • Camshaft to camshaft cover clearance
• Crankcase hole inside diameter “a” Out of specification → Replace the defective
Out of specification → Replace the crank- part(s).
case. NOTE:
Crankcase hole inside diameter Calculate the clearance by subtracting the cam-
25.000–25.021 mm (0.9843– shaft journal diameter (camshaft cover side)
0.9851 in) from the camshaft cover hole inside diameter.
Camshaft to camshaft cover

clearance
0.020–0.064 mm (0.0008–0.0025
in)
a a 9. Check:
• Camshaft drive gears
• Camshaft driven gears
• Front cylinder camshaft gears
• Rear cylinder camshaft gears
6. Measure: Chips/pitting/roughness/wear → Replace the
• Camshaft cover hole inside diameter “a” defective part(s).
Out of specification → Replace the camshaft EAS23890
cover. CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
Camshaft cover hole inside diam- The following procedure applies to all of the
eter
rocker arms and rocker arm shafts.
28.000–28.021 mm (1.1024–
1.1032 in) 1. Check:
• Rocker arm
a a 2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication
system.
3. Measure:
• Rocker arm inside diameter “a”
Rocker arm inside diameter

7. Calculate: 18.000–18.018 mm (0.7087–
• Camshaft-to-crankcase clearance 0.7094 in)
Out of specification → Replace the defective
part(s).
5-27
CAMSHAFTS
• Push rod end

Bends/damage → Replace.
2. Measure:
• Push rod runout
Valve push rod runout

0.3 mm (0.012 in)
4. Measure:
• Rocker arm shaft outside diameter “a”
Rocker arm shaft outside diame-

ter
17.976–17.991 mm (0.7077–
0.7083 in)
EAS23920
CHECKING THE VALVE LIFTERS AND

VALVE LIFTER CASES
1. Check:
• Valve lifter
Blue discoloration/excessive wear/pitting/
scratches → Replace and check the lubrica-
tion system.
2. Check:
• Valve lifter case “1”
5. Calculate: Damage/wear → Replace the valve lifter
• Rocker arm to rocker arm shaft clearance case.
NOTE: • O-rings “2”
Calculate the clearance by subtracting the rock- Damage/wear → Replace the O-ring.
er arm shaft outside diameter from the rocker
arm inside diameter.
Above 0.08 mm (0.003 in) → Replace the de- 1
fective part(s).
2
Rocker-arm-to-rocker-arm-shaft
clearance
0.009–0.042 mm (0.0004–0.0017
in)
EAS23900 3. Measure:
CHECKING THE ROCKER ARM BASES • Valve lifter outside diameter “a”
1. Check: Out of specification → Replace.
• Rocker arm base
EAS23910
CHECKING THE PUSH RODS

1. Check:
• Push rod
5-28
CAMSHAFTS
Valve lifter outside diameter (in- Valve-lifter-to-valve-lifter-hole

take) clearance
22.962–22.974 mm (0.9040– 0.026–0.059 mm (0.0010–0.0023
0.9045 in) in)
Valve lifter outside diameter (ex-
haust) EAS23930
22.962–22.974 mm (0.9040– CHECKING THE PUSH ROD COVER

0.9045 in) 1. Check:
• Push rod cover
Cranks/damage → Replace.
• Seal
• O-ring
Damage/wear → Replace the seal and O-
ring as a set.
EAS23980
CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
4. Measure: NOTE:
• Valve lifter case inside diameter “a” • Check that the decompression pin “1” projects
Out of specification → Replace. from the camshaft.
• Check that the decompression cam “2” and de-
Valve lifter hole inside diameter compression pin “1” moves smoothly.
(intake)
23.000–23.021 mm (0.9055– 1
0.9063 in)
Valve lifter hole inside diameter
(exhaust)
23.000–23.021 mm (0.9055–
0.9063 in)
2
2. Check:
• Decompression cam
• Decompression pin
ET1D71031
CHECKING THE DECOMPRESSION CAM

SPRING
5. Calculate: The following procedure applies to all of the de-
• Valve lifter-to-valve lifter case clearance compression cam springs.
NOTE: 1. Measure:
Calculate the clearance by subtracting the valve • Decompression cam spring free length “a”
lifter outside diameter from the valve lifter case Out of specification → Replace the decom-
inside diameter. pression cam spring.
Above 0.072 mm (0.0028 in) → Replace the Decompression cam spring
defective part(s). Free length
20.0 mm (0.79 in)
Limit
19.0 mm (0.75 in)
5-29
CAMSHAFTS
2. Install:
• Camshaft cover 1 “1”
• Oil delivery pipe 1 “2”
NOTE:
Tighten the camshaft cover bolts in stages and
in a crisscross pattern.
2. Measure:
• Compressed decompression cam spring 1
force “a”
Out of specification → Replace the decom-
pression cam spring.
Decompression cam spring

Installed compression spring 3. Install:
force • Straight keys
0.1335–0.1631 N (0.0300–0.0367 • Right balancer drive gear “1”
lb) (0.0136–0.0166 kgf) • Right balancer driven gear “2”
Installed length
• Camshaft driven gear
8.0 mm (0.31 in)
NOTE:
• Cover the crankcase hole with a clean rag to
prevent the straight keys from falling into the
crankcase.
• Align the punch mark “a” on the right balancer
drive gear “1” with the punch mark “b” on the
right balancer driven gear “2”.
b. Installed length b a
EAS23990 2
CHECKING THE OIL DELIVERY PIPE
1. Check: 1
• Oil delivery pipe 1
Damage → Replace.
Obstruction → Wash and blow out with com- 4. Tighten:
pressed air. • Camshaft drive gear bolt “1”
• O-rings • Right balancer driven gear bolt “2”
Camshaft drive gear bolt
EAS24030
60 Nm (6.0 m·kg, 43 ft·lb)
T.
INSTALLING THE CAMSHAFTS

R.
Right balancer driven gear bolt

1. Install: 40 Nm (4.0 m·kg, 29 ft·lb)
• Camshafts
NOTE: NOTE:
Lubricate molybdenum disulfide oil onto the • Lubricate the camshaft drive gear bolt and right
camshaft journals and lobes. balancer driven gear bolt threads with engine
oil.
5-30
CAMSHAFTS

teeth of the right balancer drive gear and right 2 1
b
• Do not damage the teeth of the right balancer
drive and right balancer driven gears. a
• After tightening the camshaft driven gear bolt, 3
remove the copper washer to clean the teeth of
the right balancer drive gear and right balancer
driven gear.
3
4
5
6 New
3 6. Tighten:
• Front cylinder camshaft gear bolt “1”
Front cylinder camshaft gear bolt

40 Nm (4.0 m·kg, 29 ft·lb)
T.
R.
NOTE:
4 • Place a folded copper washer “2” between the

teeth of the front cylinder camshaft gear and
2 rear cylinder camshaft gear in order to lock
them.
• Do not damage the teeth of the front cylinder
camshaft and rear cylinder camshaft gears.
5. Install: • After tightening the front cylinder camshaft
• Rear cylinder camshaft gear “1” gear bolt, remove the copper washer to clean
• Front cylinder camshaft gear “2” the teeth of the front cylinder camshaft and rear
• Washer “3” cylinder camshaft gears.
• Conical spring washer “4”
• Washer “5”
• Circlip “6” New 1
NOTE:
• Align the projection “a” on the washer “3” with
the punch mark “b” on the front cylinder cam- 2
shaft gear.
• Install the conical spring washer “4” as shown
• Lubricate the front cylinder camshaft gear bolt
threads with engine oil. 7. Install:
• Straight key
• Camshaft driven gear “1”
5-31
CAMSHAFTS
NOTE:
• Cover the crankcase hole with a clean rag to 1
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 2
camshaft drive gear “2”.
• Insert a cross-headed screwdriver into one of
the holes in the outer camshaft driven gear and
rotate the gear until the teeth of both driven
gears are aligned. The teeth of both camshaft EAS24050
driven gears must be aligned for installation. BLEEDING A VALVE LIFTER

A valve lifter must be bled in the following cases.
• When installing a new valve lifter
a • When the valve lifter leaks oil
1
1. Bleed:
• Valve lifter
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b a. Fill a container with kerosene and place the
valve lifter into the container as shown.
2
Pump the plunger side of the valve lifter with
a press a number of times to let in kerosene.
ECA14630
CAUTION:
• Do not pump the valve lifter excessively.
• Kerosene is highly flammable.
8. Tighten:
• Camshaft driven gear bolt “1”
Camshaft driven gear bolt 1. Kerosene

60 Nm (6.0 m·kg, 43 ft·lb) 2. Valve lifter
T.
R.
NOTE: b. Install the valve lifter into the engine.

ECA14650
• Place a folded copper washer “2” between the CAUTION:
teeth of the camshaft drive gear and camshaft
Be sure to install the valve lifter in its appro-
driven gear in order to lock them.
priate position.
• Do not damage the teeth of the camshaft drive
and camshaft driven gears. c. Start the engine and warm it up.
• After tightening the camshaft driven gear bolt, d. Stop the engine.
remove the copper washer to clean the teeth of e. Remove the camshaft sprocket cover.
the camshaft drive and camshaft driven gears. f. Rotate the camshaft until the punch mark “1”
on the camshaft driven gear aligns with the
punch mark on the camshaft drive gear as
shown. This is the condition in which piston
#1 is at top dead center (TDC).
5-32
CAMSHAFTS
NOTE:
The crankshaft can be rotated smoothly when
the spark plugs are removed.
EWA12880
WARNING
10
11
9
12
8
7
13
6
5
Be careful since the engine is hot.
14
4
15
3
16
g. With piston #1 at TDC, count the indicated
2
1
2 1 1
1918 1
number of gear teeth and place marks “2”
through “5” on the camshaft driven gear as
1 19
4 3
shown. When these marks align between the
17 8
centers of the camshaft drive and driven 2
5
16
6
gears, the corresponding valve lifter is at its
15
7
14
8
13
12
9
10
11
highest point.
1918 17 16 15
19 14
18 13
17 12
16
4 11
15 10 1. Piston #1 TDC punch mark
14 9
13 8
2. Cylinder #2 intake valve at its highest point
12 3 7
11 5 6 i. Leave the camshaft drive and driven gears
10
2
5 aligned for five minutes to allow the valve lift-
9 1 4
8 3 er to bleed.
7 2
6 5
4 3 2 1
1 j. If necessary, repeat steps (h) and (i) to bleed
other valve lifters.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24060
INSTALLING THE VALVE LIFTERS

1. Install:
• Front valve lifter case
• Rear valve lifter case
• Valve lifters
1. Piston #1 TDC punch mark
2. Cylinder #2 intake valve at its highest point Valve lifter case bolt
3. Cylinder #1 exhaust valve at its highest point 10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
4. Cylinder #1 intake valve at its highest point LOCTITE®

5. Cylinder #2 exhaust valve at its highest point
h. Rotate the crankshaft until the mark (on the NOTE:
camshaft driven gear) for the valve lifter to be • Install the valve lifter in the correct place.
bled aligns with the camshaft drive gear as • After installing the valve lifters, fill the tops of
shown. them with engine oil.
Example:
For bleeding the cylinder #2 intake valve lift-
er, align mark “2” as shown.
5-33
CAMSHAFTS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Put the rocker arm base on the cylinder head.
b. Install the push rods.
NOTE:
• Be sure to correctly install the push rods be-
tween the rocker arms and valve lifters as
shown. The illustration is viewed from the right
side of the vehicle.
E
• The lengths of push rod 1 and push rod 2 are
different. Therefore, be sure to install them in
2. Install: the proper position.
• Push rod covers “1” • Lubricate the push rod end balls with engine
NOTE: oil.
Install the push rod covers so that their paint
marks “a” are facing towards the cylinder heads.
a a
1
1
EAS24070
INSTALLING THE ROCKER ARMS AND

PUSH RODS
The following procedure applies to both cylin-
ders.
1. Install:
• Rocker arms “1”
• Rocker arm shafts “2”
(onto rocker arm base) A. Rear cylinder
NOTE: B. Front cylinder
The thread hole “a” of the rocker arm shaft must 1. Exhaust side rocker arm
face to the outside. 2. Intake side rocker arm
3. Exhaust valve lifter
4. Intake valve lifter
1 5. Push rod 1 l = 286.5 mm (11.280 in)
a 6. Push rod 2 l = 288.5 mm (11.358 in)
c. Install the rocker arm base bolts (M6) “1” and
rocker arm base bolts (M8) “2” and “3”.
NOTE:
a Tighten the rocker arm base bolts in stages and
2 in a crisscross pattern.
2. Install: Rocker arm base bolt (M6)

• Rocker arm base 10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
(with rocker arms) Rocker arm base bolt (M8)

• Push rods 24 Nm (2.4 m·kg, 17ft·lb)
5-34
CAMSHAFTS
Bolts “2”: l = 45 mm (1.77 in) ET1D71032
INSTALLING THE SHIFT PEDAL ASSEMBLY

Bolts “3”: l = 70 mm (2.76 in)
(for XV19S(C)/ XV19M(C)/ XV19CTS(C)/
1 XV19CTM(C))
2 1. Install:
NOTE:
3 Align the mark “a” on the shift pedal shaft with
the slot in the shift pedal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
EAS24080
INSTALLING THE CYLINDER HEAD

COVERS
1. Install:
• Rear cylinder head cover “1” a
• Front cylinder head cover “2”
NOTE:
Due to the small clearance between the frame
“3” cannot be installed when the cover is in
place. Set the bolts in the cylinder head cover,
and then install the cover from the right side of
the vehicle.
Cylinder head cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
Bolts “4”: l = 40 mm (1.57 in)

Bolts “5”: l = 60 mm (2.36 in)
5
4
5 2
5
5
5 1
4
5
3 5
3
5-35
CYLINDER HEADS
EAS24110
CYLINDER HEADS
Removing the cylinder heads

T.
R.
T.
R.
1
2
LT
LT
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) (3)
T.
R.
11
60 Nm (6.0 m • kg, 43 ft • Ib)
T.
R.
12
New 7
13 New
5 New
New 9
10
3 New 4
A 59Nm (5.9 m • kg, 43 ft • lb)
New 5
T.
B 66Nm (6.6 m • kg, 48 ft • lb)

R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
6 New
8 A 18Nm (1.8 m • kg, 13 ft • lb)
T.
B 17Nm (1.7 m • kg, 12 ft • lb)

R.
New 9
10 21 Nm (2.1 m • kg, 15 ft • Ib)
T.
R.

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 “CAMSHAFTS” on page 5-17.
1 Engine bracket (right upper side) 1
2 Engine bracket (left upper side) 1
3 Engine temperature sensor 1
4 Oil pipe 1 1
5 Copper washer 4
6 Copper washer 2
7 Rear cylinder head 1
8 Front cylinder head 1
9 Cylinder head gasket 2
10 Dowel pin 4
11 Rear exhaust pipe joint cover 1
12 Rear exhaust pipe joint 1
5-36
CYLINDER HEADS
Removing the cylinder heads
T.
R.
T.
R.
1
2
LT
LT
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) (3)
T.
R.
11
60 Nm (6.0 m • kg, 43 ft • Ib)
T.
R.
12
New 7
13 New
5 New
New 9
10
3 New 4
A 59Nm (5.9 m • kg, 43 ft • lb)
New 5
T.
B 66Nm (6.6 m • kg, 48 ft • lb)

R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
6 New
8 A 18Nm (1.8 m • kg, 13 ft • lb)
T.
B 17Nm (1.7 m • kg, 12 ft • lb)

R.
New 9
10 21 Nm (2.1 m • kg, 15 ft • Ib)
T.
R.

13 Rear exhaust pipe gasket 1
dure.

5-37
CYLINDER HEADS
EAS24140
REMOVING THE CYLINDER HEADS

1. Remove:
• Cylinder head nuts
NOTE:
• Loosen the nuts in the proper sequence as
shown.
• Loosen each nut 1/2 of a turn at a time. After all
of the nuts are fully loosened, remove them.
A
2. Check:
• Cylinder head
Damage/scratches → Replace.
2 3
3. Measure:
• Cylinder head warpage
Out of specification → Resurface the cylinder
4 1 head.
Warpage limit
0.03 mm (0.0012 in)
B
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge and a thickness gauge
4 1 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder
2 3 head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
A. Front cylinder NOTE:
B. Rear cylinder To ensure an even surface, rotate the cylinder
head several times.
EAS24170
CHECKING THE CYLINDER HEADS

The following procedure applies to all of the cyl-
inder heads.
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
• Valve seats ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24220
CHECKING THE OIL PIPE

1. Check:
• Oil pipe 1
Damage → Replace.
Obstruction → Wash and blow out with com-
pressed air.
5-38
CYLINDER HEADS
EAS24250
INSTALLING THE CYLINDER HEADS B

1. Install:
• Cylinder head gasket “1” New 1 4
• Dowel pins “2”
NOTE:
The “1D7” mark on the cylinder head gasket 3 2
must face up and towards the left side of the cyl-
inder.
1 New A. Front cylinder

2 B. Rear cylinder
4. Install:
• Copper washers New
• Oil pipe 1
2 • Oil pipe union bolt (M8)
Oil pipe union bolt (M8)

XV19S(C)/ XV19M(C)/
T.
R.
2. Install: XV19CTS(C)/ XV19CTM(C):
• Cylinder heads 18 Nm (1.8 m·kg, 13 ft·lb)
• Washers XV19CS(C)/ XV19C(C):
• Cylinder head nuts 17 Nm (1.7 m·kg, 12 ft·lb)
NOTE:
• Oil pipe union bolts (M10)
Lubricate the cylinder head nuts and washers
with engine oil. Oil pipe union bolt (M10)
21 Nm (2.1 m·kg, 15 ft·lb)
3. Tighten:
T.
R.
• Cylinder head nuts

NOTE:
Cylinder head nut Tighten the three union bolts evenly, and then
60 Nm (6.0 m·kg, 43 ft·lb) torque them to specification.
T.
R.
5. Install:
NOTE:
• Engine bracket (right upper side)
Tighten the cylinder head nuts in the proper • Engine bracket bolts (right upper side)
tightening sequence as shown and torque them • Engine mounting bolts (right upper side)
in two stages. • Engine bracket (left upper side)
A
• Engine bracket bolts (left upper side)
• Engine mounting bolts (left upper side)
NOTE:
3 2 • Apply locking agent (LOCTITE®) to the
threads of the engine mounting bolts (left up-
per side).
1 4 • Do not fully tighten the bolts.
6. Tighten:
• Engine mounting bolts (right upper side)
• Engine mounting bolts (left upper side)
• Engine bracket bolts (right upper side)
• Engine bracket bolts (left upper side)
5-39
CYLINDER HEADS
Engine mounting bolt (right up-

T.
R.
per side)
XV19S(C)/ XV19M(C)/
59 Nm (5.9 m·kg, 43 ft·lb)
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®
side)
53 Nm (5.3 m·kg, 38 ft·lb)
side)
53 Nm (5.3 m·kg, 38 ft·lb)
5-40
VALVES AND VALVE SPRINGS
EAS24270

Removing the valves and valve springs
1
2 1
New 6
2 3
1 6 New
2
3 7 M
6 New
7
M 8
8 3
1
7
8
2
New 6 3
7
8 E
4 5

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 spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Lower spring seat 4
8 Valve guide 4
dure.
5-41
EAS24280
3. Remove:
REMOVING THE VALVES
• Upper spring seat “1”
• Valve spring “2”
valves and related components.
• Valve “3”
NOTE: • Valve stem seal “4”
Before removing the internal parts of the cylinder • Lower spring seat “5”
head (e.g., valves, valve springs, valve seats), NOTE:
make sure the valves properly seal.
Identify the position of each part very carefully so
1. Check: that it can be reinstalled in its original place.
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-44.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat “1”.
EAS24290
CHECKING THE VALVES AND VALVE

GUIDES
valves and valve guides.
1. Measure:
• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Valve stem diameter “b”
2. Remove:
• Valve cotters Valve-stem-to-valve-guide clear-
NOTE: ance (intake)
Remove the valve cotters by compressing the 0.010–0.037 mm (0.0004–0.0015
valve springs with the valve spring compressor in)
Limit
set “1”.
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
Valve spring compressor ance (exhaust)
90890-04019 0.025–0.052 mm (0.0010–0.0020
YM-04019 in)
Limit
0.100 mm (0.0039 in)
5-42
c. After installing the valve guide, bore the valve

guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover (ø6)

90890-04064
Valve guide remover (6.0 mm)
2. Replace: YM-04064-A
• Valve guide Valve guide installer (ø6)
NOTE: 90890-04065
To ease valve guide removal and installation, Valve guide installer (6.0 mm)
and to maintain the correct fit, heat the cylinder YM-04065-A
head to 100 °C (212 °F) in an oven. Valve guide reamer (ø6)
90890-04066
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve guide reamer (6.0 mm)
a. Remove the valve guide with the valve guide YM-04066
remover “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
• Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem → Replace the valve.
b. Install the new valve guide with the valve 5. Measure:
guide installer “2” and valve guide remover • Valve margin thickness D “a”
“1”. Out of specification → Replace the valve.
Valve margin thickness D (intake)

1.15–1.45 mm (0.0453–0.0571 in)
Limit
0.4 mm (0.02 in)
Valve margin thickness D (ex-
haust)
1.15–1.45 mm (0.0453–0.0571 in)
Limit
0.4 mm (0.02 in)
5-43
Valve seat width C (intake)

1.10–1.30 mm (0.0433–0.0512 in)
Limit
2.0 mm (0.08 in)
Valve seat width C (exhaust)
1.10–1.30 mm (0.0433–0.0512 in)
Limit
2.0 mm (0.08 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
NOTE:
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Valve stem runout a. Apply Mechanic’s blueing dye (Dykem) “b”
0.010 mm (0.0004 in) onto the valve face.
b. Install the valve into the cylinder head.

EAS24300
CHECKING THE VALVE SEATS c. Press the valve through the valve guide and
The following procedure applies to all of the onto the valve seat to make a clear impres-
valves and valve seats. sion.
1. Eliminate: d. Measure the valve seat width.
• Carbon deposits NOTE:
(from the valve face and valve seat) Where the valve seat and valve face contacted
2. Check: one another, the blueing will have been re-
• Valve seat moved.
Pitting/wear → Replace the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• Valve seat width C “a” 4. Lap:
Out of specification → Replace the cylinder • Valve face
head. • Valve seat
NOTE:
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
5-44
ECA13790
g. Apply Mechanic’s blueing dye (Dykem) “b”
CAUTION: onto the valve face.
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
h. Install the valve into the cylinder head.

i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
b. Apply molybdenum disulfide oil onto the sion.
valve stem. j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
c. Install the valve into the cylinder head.

d. Turn the valve until the valve face and valve ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
seat are evenly polished, then clean off all of EAS24310
the lapping compound. CHECKING THE VALVE SPRINGS

NOTE: The following procedure applies to all of the
valve springs.
For the best lapping results, lightly tap the valve
1. Measure:
seat while rotating the valve back and forth be-
• Valve spring free length “a”
tween your hands.
spring.
Free length (intake)

46.71 mm (1.84 in)
Limit
44.71 mm (1.76 in)
Free length (exhaust)
46.71 mm (1.84 in)
Limit
44.71 mm (1.76 in)
e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
5-45
2. Measure: EAS24340
• Compressed valve spring force “a” INSTALLING THE VALVES

Out of specification → Replace the valve The following procedure applies to all of the
spring. valves and related components.
1. Deburr:
Installed compression spring • Valve stem end
force (intake) (with an oil stone)
217.00–249.00 N (48.78–55.98 lb)
(22.13–25.39 kgf)
Installed compression spring
force (exhaust)
217.00–249.00 N (48.78–55.98 lb)
(22.13–25.39 kgf)
Installed length (intake)
32.66 mm (1.29 in)
Installed length (exhaust)
32.66 mm (1.29 in)
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2”
(with the recommended lubricant)
Molybdenum disulfide oil
b. Installed length
3. Measure:
• Valve spring tilt “a”
spring.
Spring tilt (intake)

2.5 °/2.0 mm 3. Install:
Spring tilt (exhaust)
• Valve guide “1”
2.5 °/2.0 mm
• Lower spring seat “2”
• Valve stem seal “3”
• Valve “4”
• Valve spring “5”
• Upper spring seat “6”
(into the cylinder head)
5-46
NOTE: 5. To secure the valve cotters onto the valve

• Make sure each valve is installed in its original stem, lightly tap the valve tip with a soft-face
place. hammer.
ECA13800
• Install the valve springs with the larger pitch “a” CAUTION:
facing up.
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
4. Install:
• Valve cotters
NOTE:
Install the valve cotters by compressing the
valve springs with the valve spring compressor
set “1”.
Valve spring compressor

90890-04019
YM-04019
5-47
CYLINDERS AND PISTONS
EAS24360

Removing the cylinders and pistons
2
8
New 3
9
8
9
10
10
E
4
5 New 7
E
E
1 5 6
6 5 New
7 New 5
New
New 3
4

Cylinder heads Refer to “CYLINDER HEADS” on page 5-36.
1 Front cylinder 1
2 Rear cylinder 1
3 Cylinder gasket 2
4 Dowel pin 4
5 Circlip 4
6 Piston pin 2
7 Piston 2
8 Top ring 2
9 2nd ring 2
10 Oil ring 2
dure.
5-48
EAS24380
REMOVING THE PISTON NOTE:

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECA13810
CAUTION:
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 pin clip from falling into the crank-
case.
• For reference during installation, put an identi- EAS24410
fication mark on each piston crown. CHECKING THE CYLINDERS AND PISTONS
• Before removing the piston pin, deburr the pis- The following procedure applies to all of the cyl-
ton pin clip’s groove and the piston’s pin bore inders and pistons.
area. If both areas are deburred and the piston 1. Check:
pin is still difficult to remove, remove it with the • Piston wall
piston pin puller set “4”. • Cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
Piston pin puller set rings as a set.
90890-01304 2. Measure:
Piston pin puller
• Piston-to-cylinder clearance
YU-01304
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
3 bore gauge.
NOTE:
1 Measure cylinder bore “C” by taking side-to-side
2 and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
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)
“C” = maximum of D1–D6

“T” = maximum of D1 or D2 - maximum of D5
or D6
“R” = maximum of D1, D3 or D5 - minimum of
D2, D4 or D6
2. Remove:
• Top ring
• 2nd ring
• Oil ring
5-49
EAS24430
CHECKING THE PISTON RINGS

1. Measure:
• Piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clearance,
eliminate any carbon deposits from the piston
ring grooves and piston rings.
b. If out of specification, rebore or replace the
cylinder, and replace the piston and piston Piston ring
rings as a set. Top ring
c. Measure piston skirt diameter D “a” with the Ring side clearance
micrometer. 0.030–0.080 mm (0.0012–
0.0032 in)
Piston Limit
Diameter D 0.120 mm (0.0047 in)
99.960–99.975 mm (3.9354– 2nd ring
3.9360 in) Ring side clearance
0.030–0.070 mm (0.0012–
0.0028 in)
Limit
0.120 mm (0.0047 in)
b. 10 mm (0.39 in) from the bottom edge of the

piston
d. If out of specification, replace the piston and
piston rings as a set. 2. Install:
e. Calculate the piston-to-cylinder clearance • Piston ring
with the following formula. (into the cylinder)
• Piston-to-cylinder clearance = NOTE:
Cylinder bore “C” - Level the piston ring into the cylinder with the
Piston skirt diameter “D”
piston crown.
Piston-to-cylinder clearance
0.025–0.050 mm (0.0010–0.0020
in)
Limit
0.15 mm (0.0059 in)
f. If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. 10 mm (0.39 in)
5-50
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring
3. Measure:
Top ring
End gap (installed) • Piston pin bore diameter “b”
0.20–0.35 mm (0.0079–0.0138 Out of specification → Replace the piston.
in)
Limit Piston pin bore inside diameter
0.55 mm (0.0217 in) 23.004–23.015 mm (0.9057–
2nd ring 0.9061 in)
End gap (installed) Limit
0.45–0.60 mm (0.0177–0.0236 23.045 mm (0.9073 in)
in)
Limit
0.95 mm (0.0374 in)
Oil ring
End gap (installed)
0.20–0.70 mm (0.0079–0.0276
in)
EAS24440
CHECKING THE PISTON PINS

The following procedure applies to all of the pis-
ton pins. 4. Calculate:
1. Check: • Piston-pin-to-piston-pin-bore clearance
• Piston pin Out of specification → Replace the piston pin
Blue discoloration/grooves → Replace the and piston as a set.
piston pin and then check the lubrication sys-
• Piston-pin-to-piston-pin-bore clearance =
tem.
Piston pin bore diameter “b” -
2. Measure: Piston pin outside diameter “a”
• Piston pin outside diameter “a”
Out of specification → Replace the piston pin.
Piston-pin-to-piston-pin-bore
Piston pin outside diameter clearance
22.991–23.000 mm (0.9052– 0.004–0.024 mm (0.00016–
0.9055 in) 0.00094 in)
Limit
22.971 mm (0.9044 in) EAS24460
INSTALLING THE PISTONS AND

CYLINDERS
The following procedure applies to all of the pis-
tons and cylinders.
1. Install:
• Top ring “1”
• 2nd ring “2”
• Lower oil ring rail “3”
• Upper oil ring rail “4”
• Oil ring expander “5”
5-51
NOTE: 3. Lubricate:
Be sure to install the piston rings so that the • Piston
manufacturer’s marks or numbers face up. • Piston rings
• Cylinder
Engine oil
4. Offset:
• Piston ring end gaps
A
90 ˚
d.e b
2. Install:
• Piston “1”
• Piston pin “2” 90 ˚
• Piston pin clips “3” New
NOTE: a.c
• Apply engine oil onto the piston pin. 45 ˚
• Make sure the arrow mark “a” on the piston fac- a. Top ring
es towards the front of the vehicle. b. Upper oil ring rail
• Before installing the piston pin clips, cover the c. Oil ring expander
crankcase opening with a clean rag to prevent d. Lower oil ring rail
the clip from falling into the crankcase. e. 2nd ring
• Install the piston pin clips, so that the clip ends A. forward
are 3 mm (0.12 in) “b” or more from the cutout
in the piston. 5. Install:
• Reinstall each piston into its original cylinder • Cylinder “1”
(numbering order starting from the left: #1 to NOTE:
#2). While compressing the piston rings with one
hand, install the cylinder with the other hand.
3 New
5-52
CLUTCH
EAS25060
CLUTCH
Removing the clutch cover
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
2
8
3
8
(5)
New 7 5 4
6
10 Nm (1.0 m • kg, 7.2 ft • Ib) (11) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
R.
R.

Drain.
page 3-11.
Left side cover 4-1.
Horn 1/Canister For California only
Left rider footrest assembly/Shift rod/Sidestand Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “GENERATOR AND STARTER
Generator cover CLUTCH” on page 5-77.
Drive pulley case page 5-86.
1 Crankshaft position sensor coupler 1 Disconnect.
2 Shift arm 1
3 Protector 1 For XV19CS(C)/ XV19C(C)
4 Fuel tank breather/overflow pipe bracket 1 For XV19CS(C)/ XV19C(C)
For USA only
5 Fuel tank breather/overflow pipe holder bracket 1 For XV19CS(C)/ XV19C(C)
5-53
CLUTCH
Removing the clutch cover
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
2
8
3
8
(5)
New 7 5 4
6
10 Nm (1.0 m • kg, 7.2 ft • Ib) (11) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
R.
R.

6 Clutch cover 1
7 Clutch cover gasket 1
8 Dowel pin 2
dure.
5-54
CLUTCH
Removing the crankshaft position sensor
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
5 LT
LT LT
5 3
LT LT 4
5 6 LT
New 1
LS

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
dure.
5-55
CLUTCH
Removing the clutch
LS
28
27 26 25
24
New
19
23 E
E
20 18 105 Nm (10.5 m • kg, 75 ft • lb)
21 17
T.
R.
22 16
23
15 14
32 13 12 New
New
33
9
31
30 29 B
11
65 10
E A
E
100 Nm (10.0 m kg, 72 ft lb)
• • 8
7
T.
New
R.
85 Nm (8.5 m • kg, 61 ft • Ib) LS (6)

4
T.
R.
E 3 2 1
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
R.

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 Clutch boss nut 1
11 Washer 1
12 Wire circlip 1
13 Clutch plate 1
14 Friction plate 3 1 Inside diameter: 135 mm (5.31 in)
15 Clutch damper spring 1
16 Clutch damper spring seat 1
17 Clutch boss 1
5-56
CLUTCH
Removing the clutch
LS
28
27 26 25
24
New
19
23 E
E
20 18 105 Nm (10.5 m • kg, 75 ft • lb)
21 17
T.
R.
22 16
23
15 14
32 13 12 New
New
33
9
31
30 29 B
11
65 10
E A
E
100 Nm (10.0 m kg, 72 ft lb)
• • 8
7
T.
New
R.
85 Nm (8.5 m • kg, 61 ft • Ib) LS (6)

4
T.
R.
E 3 2 1
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
R.

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
5-57
CLUTCH
Removing the clutch
LS
28
27 26 25
24
New
19
23 E
E
20 18 105 Nm (10.5 m • kg, 75 ft • lb)
21 17
T.
R.
22 16
23
15 14
32 13 12 New
New
33
9
31
30 29 B
11
65 10
E A
E
100 Nm (10.0 m kg, 72 ft lb)
• • 8
7
T.
New
R.
85 Nm (8.5 m • kg, 61 ft • Ib) LS (6)

4
T.
R.
E 3 2 1
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
R.

33 Washer 1
dure.

5-58
CLUTCH
Removing the left balancer
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
12 New
(6)
9
8
10
LS
2
1 11
2
LS
New 3 (3)
LT
5 E
4 LS
6 3 New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
7
R.
E
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.

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 weight 1 1
10 Left balancer weight 2 1
11 Left balancer driven gear housing 1
12 Gasket 1
dure.
5-59
CLUTCH
Removing the clutch master cylinder
4 1
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.
13
New 10 6 S
7
9 5
12 8
11
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Drain.
Clutch fluid Refer to “BLEEDING THE HYDRAULIC
CLUTCH SYSTEM” on page 3-15.
1 Left rearview mirror 1
2 Clutch master cylinder reservoir cap 1
Clutch master cylinder reservoir diaphragm
3 1
holder
4 Clutch master cylinder reservoir diaphragm 1
5 Clutch lever 1
6 Clutch master cylinder push rod pin 1
8 Clutch switch 1
9 Clutch hose union bolt 1
10 Copper washer 2
11 Clutch hose 1
13 Clutch master cylinder 1
dure.
5-60
CLUTCH
Disassembling the clutch master cylinder
5 New 6
3 New
2

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
cedure.
5-61
CLUTCH
Removing the clutch release cylinder
19 Nm (1.9 m • kg, 13 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
*
LT
LT
New 3
1
2
6
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Drain.
Clutch fluid Refer to “BLEEDING THE HYDRAULIC
1 Clutch pipe union bolt cap 1
2 Clutch pipe union bolt 1
3 Copper washer 2
4 Clutch pipe 1
5 Clutch release cylinder 1
6 Dowel pin 2
dure.
* XV19CS(C)/ XV19C(C)
5-62
CLUTCH
Disassembling the clutch release cylinder
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
S
New 4
2
S
1

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
cedure.
5-63
CLUTCH
EAS25080
REMOVING THE CLUTCH Sheave holder

1. Loosen: 90890-01701
• Clutch boss nut “1” Primary clutch holder
NOTE: YS-01880-A
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut.
Universal clutch holder

90890-04086
YM-91042
3 2
1
2. Remove:
• Clutch boss nut “1” 3
• Conical spring washer “2” 2
• Washer “3”
• Clutch boss assembly “4” ET1D71021
NOTE: REMOVING THE LEFT BALANCER DRIVE

There is a built-in damper between the clutch GEAR
boss and the clutch plate. It is not necessary to 1. Loosen:
remove the wire circlip “5” and disassemble the • Left balancer drive gear bolt “1”
built-in damper unless there is serious clutch NOTE:
chattering. While the holding the generator rotor “2” with the
primary sheave holder “3”, loosen the left bal-
ancer drive gear bolt.
4
Sheave holder
90890-01701
5
3 YS-01880-A
2
1
EAS25090
REMOVING THE PRIMARY DRIVE GEAR

1. Loosen:
• Primary drive gear bolt “1”
1
NOTE:
While holding the generator rotor “2” with the
sheave holder “3”, loosen the primary drive gear
bolt.
5-64
CLUTCH
A B
3
2
EAS25100 A. Friction plate 1, 3

CHECKING THE FRICTION PLATES B. Friction plate 2
The following procedure applies to all of the fric-
tion plates. EAS25110
CHECKING THE CLUTCH PLATES

1. Check:
• Friction plate
clutch plates.
Damage/wear → Replace the friction plates
1. Check:
as a set.
• Clutch plate
2. Measure:
Damage → Replace the clutch plates as a
• Friction plate thickness
set.
Out of specification → Replace the friction
2. Measure:
plates as a set.
• Clutch plate warpage
NOTE: (with a surface plate and thickness gauge “1”)
Measure the friction plate at four places. Out of specification → Replace the clutch
plates as a set.
Friction plate 1, 3 thickness
2.90–3.10 mm (0.114–0.122 in) Thickness gauge
Wear limit 90890-03180
2.80 mm (0.110 in) Feeler gauge set
Friction plate 2 thickness YU-26900-9
2.92–3.08 mm (0.115–0.121 in)
Wear limit
2.82 mm (0.111 in) Clutch plate thickness
1.90–2.10 mm (0.075–0.083 in)
Warpage limit
0.20 mm (0.0079 in)
EAS25130
CHECKING THE CLUTCH SPRING PLATE

1. Check:
• Clutch spring plate
Damage → Replace.
5-65
CLUTCH
2. Check: • Bearing
• Clutch spring plate seat Damage/wear → Replace.
Damage → Replace.
EAS25190
EAS25150 CHECKING THE CLUTCH PUSH RODS

CHECKING THE CLUTCH HOUSING 1. Check:
1. Check: • O-ring
• Clutch housing dogs • Short clutch push rod
Damage/pitting/wear → Deburr the clutch • Long clutch push rod
housing dogs or replace the clutch housing. • Ball
NOTE: Cracks/damage/wear → Replace the defec-
Pitting on the clutch housing dogs will cause er- tive part(s).
ratic clutch operation. 2. Measure:
• Long clutch push rod bending limit
part(s).
Long clutch push rod bending

limit
0.30 mm (0.0118 in)
EAS25200
CHECKING THE PRIMARY DRIVE GEAR

1. Check:
• Primary drive gear
2. Check:
Damage/wear → Replace the primary drive
• Bearing
and primary driven gears as a set.
Damage/wear → Replace the bearing and
Excessive noise during operation → Replace
clutch housing.
the primary drive and primary driven gears as
EAS25160 a set.
CHECKING THE CLUTCH BOSS
EAS25210
1. Check:
CHECKING THE PRIMARY DRIVEN GEAR
• Clutch boss splines
1. Check:
Damage/pitting/wear → Replace the clutch
• Primary driven gear “1”
boss.
Damage/wear → Replace the primary drive
NOTE: and primary driven gears as a set.
Pitting on the clutch boss splines will cause er- Excessive noise during operation → Replace
ratic clutch operation. the primary drive and primary driven gears as
a set.
EAS25170
CHECKING THE PRESSURE PLATE ET1D71033
1. Check: CHECKING THE LEFT BALANCER GEARS

• Pressure plate 1. Check:
Cracks/damage → Replace. • Left balancer drive gear
• Left balancer driven gear
5-66
CLUTCH
• Left balancer idle gear NOTE:

Burrs/chips/roughness/wear → Replace the Calculate the clearance by subtracting the left
defective part(s). balancer driven gear housing outside diameter
2. Measure: from the left balancer driven gear inside diame-
• Left balancer driven gear inside diameter “a” ter.
Left balancer driven gear inside Left-balancer-driven-gear-to-left-

diameter “a” balancer-driven-gear-housing
59.010–59.028 mm (2.323–2.324 clearance
in) 0.050–0.103 mm (0.0020–0.0041
Limit in)
59.100 mm (2.327 in)
ET1D71022
INSTALLING THE LEFT BALANCER DRIVE

a GEAR
1. Install:
• Left balancer weight 1 “1”
• Left balancer weight 2 “2”
• Left balancer driven gear “3”
NOTE:
Make sure that the punch marks “a” on the left
balancer driven gear are facing toward left bal-
ancer weight 2.
3. Measure:
• Left balancer driven gear housing outside di- Left balancer weight bolt
ameter “a” 10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
Out of specification → Replace. LOCTITE®
Left balancer driven gear hous-

ing outside diameter “a” 3
58.925–58.960 mm (2.320–2.321
in) 2
Limit a
58.900 mm (2.318 in)
a
1
2. Remove:
• Generator rotor
Refer to “REMOVING THE GENERATOR”
on page 5-79.
3. Align:
• Mark “a” on the generator drive gear of the
4. Calculate: crankshaft
• Left-balancer-driven-gear-to-left-balancer- (with the mark “b” on the generator shaft driv-
driven-gear-housing clearance en gear)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the defective a. Turn the crankshaft.
part(s). b. When the front and rear pistons are near
TDC, align the mark “a” on the generator
drive gear of the crankshaft with the mark “b”
on the generator shaft driven gear.
5-67
CLUTCH
b a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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” 3
• Left balancer driven gear “3” 2
NOTE:
• Align the punch mark “a” on the left balancer EAS25230
drive gear with the punch mark “b” on the left INSTALLING THE PRIMARY DRIVE GEAR
balancer idle gear. 1. Install:
• Align the punch marks “c” on the left balancer • Washer
idle gear with the punch marks “d” on the left • Straight key
balancer driven gear. • Primary drive gear
• Crankshaft position sensor rotor “1”
• Spacer
c d 3 • Primary drive gear bolt “2”
Primary drive gear bolt

100 Nm (10.0 m·kg, 72 ft·lb)
T.
R.
1 EC1D71007
CAUTION:
a
b 2 The timing marks on the crankshaft position
sensor rotor must face outside.
6. Tighten: NOTE:
• Left balancer drive gear bolt “1” • Lubricate the primary drive gear bolt threads
Left balancer drive gear bolt with engine oil.
40 Nm (4.0 m·kg, 29 ft·lb) • While holding the generator rotor “3” with the
T.
sheave holder “4”, tighten the primary drive

R.
NOTE: gear bolt.

While holding the generator rotor “2” with the
sheave holder “3”, tighten the left balancer drive Sheave holder
gear bolt. 90890-01701
YS-01880-A
Sheave holder
90890-01701
YS-01880-A
5-68
CLUTCH
• Washer
• Clutch boss nut “3”
Clutch boss nut

105 Nm (10.5 m·kg, 75 ft·lb)
T.
1
R.
NOTE:
2 • Lubricate the clutch boss nut threads and con-
ical spring washer mating surfaces with engine
oil.
• While holding the clutch boss with the univer-
sal clutch holder “4”, tighten the clutch boss
nut.
• Stake the clutch boss nut “3” at a cutout “b” in
the main axle.
4
3
Universal clutch holder
90890-04086
EAS25260
INSTALLING THE CLUTCH YM-91042

1. Install:
• Clutch housing 4 1 2
• Thrust washer
NOTE:
• Lubricate the clutch housing bearings with en- a
gine oil.
• Make sure that the primary driven gear teeth
b
and primary drive gear teeth mesh correctly.
3
• Make sure that the primary driven gear teeth
and oil pump driven gear teeth mesh correctly.
2. Install: 4. Lubricate:
• Clutch boss assembly “1” • Friction plates
• Clutch plates
NOTE:
• Install the clutch damper spring “2” with the
“OUTSIDE” mark facing out. Recommended lubricant
• If the wire circlip “3” has been removed, care- Engine oil
fully install a new one.
5. Install:
• Friction plates 2 “1”
1 • Clutch plates
• Friction plate 1 “2”
NOTE:
• First, install a friction plate and then alternate
between a clutch plate and a friction plate.
• Align a projection on each friction plate 2 “1”
2
with the “ ” mark “a” on the clutch housing
New 3 and align a projection on friction plate 1 “2” with
3. Install: the punch mark “b” on the housing.
• Clutch boss “1”
5-69
CLUTCH
b a
a
1
b
2 1
b
a
6. Install: EAS25280
• Clutch spring plate DISASSEMBLING THE CLUTCH MASTER

• Clutch spring plate retainer CYLINDER
NOTE:
Clutch spring plate retainer bolt
Before disassembling the clutch master cylinder,
8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
drain the clutch fluid from the entire clutch sys-

R.
tem.
NOTE:
Tighten the clutch spring plate retainer bolts in 1. Remove:
stages and in a crisscross pattern. • Clutch hose union bolt “1”
7. Apply: • Clutch hose “3”
• Sealant
NOTE:
(onto the crankshaft position sensor lead
grommet) To collect any remaining clutch fluid, place a
container under the master cylinder and the end
Yamaha bond No. 1215 of the clutch hose.
90890-85505
3
ET1D71037
CHECKING THE CLUTCH MASTER

8. Install: CYLINDER
• Shift arm “1” 1. Check:
• Clutch master cylinder
Shift arm bolt Damage/scratches/wear → Replace.
12 Nm (1.2 m·kg, 8.7 ft·lb) • Clutch fluid delivery passage
T.
R.
(clutch master cylinder body)

NOTE: Obstruction → Blow out with compressed air.
Install the shift arm “1” with its slot “a” aligned 2. Check:
with the mark “b” in end of the shift shaft. • Clutch master cylinder kit
Damage/scratches/wear → Replace.
3. Check:
• Clutch master cylinder reservoir
5-70
CLUTCH
• Clutch master cylinder reservoir diaphragm EWA1D77010
Damage/wear → Replace. WARNING

4. Check: Proper clutch hose routing is essential to in-
• Clutch hose sure safe vehicle operation. Refer to “CABLE
Cracks/damage/wear → Replace. ROUTING (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C))” on page 2-51
EAS25300
ASSEMBLING THE CLUTCH MASTER
CYLINDER
EW1D71010
NOTE:
WARNING
• Install the clutch hose at a right angle to the
• Before installation, all internal clutch com- clutch master cylinder as shown in the illustra-
ponents must be cleaned and lubricated tion.
with clean or new clutch fluid. • While holding the clutch hose, tighten the
• Never use solvents on internal clutch com- union bolt.
ponents. • Turn the handlebar to the left and right to make
sure the clutch hose does not touch other parts
Recommended clutch fluid (e.g., wire harness, cables, leads). Correct if
Brake fluid DOT 4 necessary.
EAS25310
A
INSTALLING THE CLUTCH MASTER
CYLINDER
1. Install:
• Clutch master cylinder “1”
• Clutch master cylinder holder “2”
1
Clutch master cylinder holder 2
bolt
T.
R.
10 Nm (1.0 m·kg, 7.2 ft·lb) 5–25˚
B
NOTE:
• Align the end of the clutch lever holder with the
punch mark “a” on the handlebar.
• First, tighten the rear bolt, then the front bolt.
15–35˚

XV19CTM(C)
2 a 3. Fill:
2. Install: (with the specified amount of the recom-
• Copper washers New mended clutch fluid)
• Clutch hose “1”
Recommended clutch fluid
• Clutch hose union bolt “2” Brake fluid DOT 4
Clutch hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
5-71
CLUTCH
EWA13370 ET1D71004
WARNING REMOVING THE CLUTCH RELEASE

• Use only the designated clutch fluid. Other CYLINDER
clutch fluids may cause the rubber seals to 1. Remove:
deteriorate, causing leakage and poor • Clutch pipe union bolt “1”
clutch performance. • Copper washers “2”
• Refill with the same type of clutch fluid that • Clutch pipe “3”
is already in the system. Mixing clutch flu- NOTE:
ids may result in a harmful chemical reac- Put the end of the clutch pipe into a container
tion, leading to poor clutch performance. and pump out the clutch fluid carefully.
not enter the clutch fluid reservoir. Water
the clutch fluid and could cause vapor lock.
ECA13420
CAUTION: 1
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately. 3
2
NOTE:
EAS25330
In order to ensure a correct reading of the clutch
CHECKING THE CLUTCH RELEASE
fluid level, make sure the top of the reservoir is
CYLINDER
horizontal.
Recommended clutch component replace-
4. Bleed: ment schedule
• Clutch system
Refer to “BLEEDING THE HYDRAULIC Piston seal Every two years
CLUTCH SYSTEM” on page 3-15. Clutch hose Every four years
5. Check: Every two years and
• Clutch fluid level Clutch fluid whenever the clutch
Below the minimum level mark “a” → Add the is disassembled
recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID 1. Install:
LEVEL” on page 3-14. • Clutch release cylinder body
Cracks/damage → Replace the clutch re-
lease cylinder.
2. Check:
• Clutch release cylinder “1”
• Clutch release cylinder piston “2”
Rust/scratches/wear → Replace the clutch
release cylinder and clutch release cylinder
piston as a set.
1
6. Check:
• Clutch lever operation
2
Soft or spongy feeling → Bleed the clutch
system.
5-72
CLUTCH
EAS25340
2. Fill:
ASSEMBLING THE CLUTCH RELEASE
CYLINDER
EW1D71006
WARNING mended clutch fluid)
• Before installation, all internal clutch com- Recommended clutch fluid
ponents must be cleaned and lubricated Brake fluid DOT 4
with clean or new clutch fluid.
• Never use solvents on internal clutch com- EWA13370
ponents as they will cause the piston seal WARNING

to swell and distort. • Use only the designated clutch fluid. Other
• Whenever a clutch release cylinder is dis- clutch fluids may cause the rubber seals to
assembled, replace the piston seal. deteriorate, causing leakage and poor
clutch performance.
Recommended clutch fluid • Refill with the same type of clutch fluid that
Brake fluid DOT 4 is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
EAS25350 tion, leading to poor clutch performance.
INSTALLING THE CLUTCH RELEASE • When refilling, be careful that water does
CYLINDER not enter the clutch fluid reservoir. Water
1. Install: will significantly lower the boiling point of
• Copper washers New the clutch fluid and could cause vapor lock.
• Clutch pipe “1” ECA13420
• Clutch pipe union bolt “2” CAUTION:

Clutch pipe union bolt plastic parts. Therefore, always clean up any
26 Nm (2.6 m·kg, 19 ft·lb)
T.
spilt clutch fluid immediately.

R.
EWA1D77009
NOTE:
WARNING
In order to ensure a correct reading of the clutch
Proper clutch pipe routing is essential to in-
fluid level, make sure that the top of the reservoir
sure safe vehicle operation. Refer to “CABLE
is horizontal.
ROUTING (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C))” on page 2-51 3. Bleed:
and “CABLE ROUTING (for XV19CS(C)/ • Clutch system
XV19C(C))” on page 2-67. Refer to “BLEEDING THE HYDRAULIC
EC1D71005 CLUTCH SYSTEM” on page 3-15.
CAUTION: 4. Check:
When installing the clutch pipe onto the • Clutch fluid level
clutch release cylinder, make sure the pipe Below the minimum level mark “a” → Add the
“a” touches the projection “b” on the clutch recommended clutch fluid to the proper level.
release cylinder. Refer to “CHECKING THE CLUTCH FLUID
1
b
5-73
CLUTCH
5. Check:
• Clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
5-74
SHIFT SHAFT
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
LT
New
LS
1
2
1
4
7 3
E
New 2
1
6
5
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

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 spring stopper 1
dure.
5-75
SHIFT SHAFT
EAS25420
CHECKING THE SHIFT SHAFT

1. Check: 1
• Shift shaft
Bends/damage/wear → Replace.
3
• Shift shaft spring 2
EAS25430
CHECKING THE STOPPER LEVER

1. Check:
• Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
• Stopper lever spring
EAS25450
INSTALLING THE SHIFT SHAFT

1. Install:
• Stopper lever “1”
• Collar
• Stopper lever bolt “2”
• Stopper lever spring “3”
Stopper lever bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
LOCTITE®
NOTE:
• Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss “4”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
4
3
2
2. Install:
• Washers
• Circlips
• Shift shaft spring “1”
• Shift shaft “2”
NOTE:
Hook the end of the shift shaft spring onto the
shift shaft spring stopper “3”.
5-76
GENERATOR AND STARTER CLUTCH
EAS24480

Removing the stator coil
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New LS
LT
6
5
2
New
LS
7 LT
LT
New
5
4 New E
LT
3 (5)

T.
T.
R.
R.

Drain.
page 3-11.
Lead cover Refer to “BELT DRIVE” on page 4-90.
Clutch pipe Refer to “CLUTCH” on page 5-53.
1 Stator coil coupler 1 Disconnect.
3 Generator cover 1
4 Generator cover gasket 1
5 Dowel pin 2
6 Stator coil lead holder 1
7 Stator coil 1
dure.
5-77
Removing the generator rotor
7
9
24 Nm (2.4 m • kg, 17 ft • Ib)

8
T.
R.
LT
6
4 3 E
LT
LT 1
2
E
(6) E
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
80 Nm (8.0 m • kg, 58 ft • Ib)

.
T
R.

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
dure.
5-78
EAS24490
REMOVING THE GENERATOR NOTE:

1. Remove: While holding the generator rotor “1” with the
• Generator rotor bolt “1” sheave holder “2”, loosen the starter clutch
• Washer bolts.
NOTE:
While holding the generator rotor “2” with the Sheave holder
sheave holder “3”, loosen the generator rotor 90890-01701
bolt.
YS-01880-A
Sheave holder
90890-01701
YS-01880-A
1 2
EAS24570
CHECKING THE STARTER CLUTCH

3 1. Check:
1 2 • Starter clutch rollers
2. Remove: 2. Check:
• Generator rotor “1” • Starter clutch idle gear
(with the rotor puller “2”) • Starter clutch gear
• Woodruff key Burrs/chips/roughness/wear → Replace the
Rotor puller defective part(s).
90890-01080 3. Check:
Stator rotor puller • Starter clutch gear’s contacting surfaces
YM-01080-A Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear “1” onto the
starter clutch and hold the generator rotor “2”.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
2 1 starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counter-
EAS24560
clockwise “B”, it should turn freely, otherwise
REMOVING THE STARTER CLUTCH the starter clutch is faulty and must be re-
1. Remove: placed.
• Starter clutch bolts
• Starter clutch
5-79
• Washer
• Generator rotor bolt “2”
NOTE:
• Clean the tapered portion of the generator
shaft and the generator rotor hub.
• When installing the rotor, make sure the woo-
druff key is properly seated in the key way of
the generator shaft.
• Lubricate the generator rotor bolt threads and
washer mating surfaces with engine oil.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71020
CHECKING THE TORQUE LIMITER

1. Check:
• Torque limiter
NOTE:
Do not disassemble the torque limiter.
2 1
EAS24600
INSTALLING THE STARTER CLUTCH 2. Tighten:

1. Install: • Generator rotor bolt “1”
• Starter clutch
Generator rotor bolt
Starter clutch bolt 80 Nm (8.0 m·kg, 58 ft·lb)
T.
R.
24 Nm (2.4 m·kg, 17 ft·lb)

T.
R.
LOCTITE® NOTE:
While holding the generator rotor “2” with a
NOTE:
sheave holder “3”, tighten the generator rotor
While holding the generator rotor “1” with the bolt.
sheave holder “2”, tighten the starter clutch
bolts.
Sheave holder
90890-01701
Sheave holder Primary clutch holder
90890-01701 YS-01880-A
YS-01880-A
3
1 2 1 2
3. Apply:
• Sealant
EAS24510
(onto the stator coil lead grommet)
INSTALLING THE GENERATOR
1. Install: Yamaha bond No. 1215
• Woodruff key 90890-85505
• Generator rotor “1” (Three Bond No.1215®)
5-80
5-81
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

1 Starter motor lead 1 Disconnect.
2 Starter motor 1
dure.
5-82
ELECTRIC STARTER
Disassembling the starter motor
LS
LS
New
1 New 3 2
New 4
10 New
New
11
12
7
6
8
New 10 9

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 Gasket 2
11 Armature assembly 1
12 Starter motor yoke 1
cedure.
5-83
ELECTRIC STARTER
EAS24790
CHECKING THE STARTER MOTOR Pocket tester

1. Check: 90890-03112
• Commutator Analog pocket tester
Dirt → Clean with 600 grit sandpaper. YU-03112-C
2. Measure:
• Commutator diameter “a”
Out of specification → Replace the starter Armature coil
Commutator resistance “1”
motor.
0.0081–0.0099 Ω at 20 °C (68 °F)
Limit Insulation resistance “2”
27.5 mm (1.08 in) Above 1 MΩ at 20 °C (68 °F)
3. Measure: b. If any resistance is out of specification, re-

• Mica undercut “a” place the starter motor.
Out of specification → Scrape the mica to the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
proper measurement with a hacksaw blade 5. Measure:

that has been grounded to fit the commutator. • Brush length “a”
Out of specification → Replace the brushes
Mica undercut (depth) as a set.
1.50 mm (0.06 in)
Limit
NOTE: 5.00 mm (0.20 in)
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Measure:
• Brush spring force
4. Measure: Out of specification → Replace the brush
• Armature assembly resistances (commutator springs as a set.
and insulation)
Out of specification → Replace the starter Brush spring force
motor. 7.36–11.04 N (26.49–39.74 oz)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(750–1126 gf)
a. Measure the armature assembly resistances
with the pocket tester.
5-84
ELECTRIC STARTER
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearings
• Oil seal
Damage/wear → Replace the defective
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke “1”
NOTE:
Align the projection “a” on the brush holder with
the slot “b” in the starter motor yoke.
1 b
a
2. Install:
• Starter motor front cover “1”
NOTE:
Align the match mark “a” on the starter motor
yoke with the match mark “b” on the starter mo-
tor front cover.
a b
5-85
TRANSFER GEAR CASE
EAS25460
TRANSFER GEAR CASE

Removing the middle driven shaft
3 18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
(5)
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)

T.
R.
(7)
LT New
LS
13 5
New
5
New
7
LS
7 4 New
12
6 New 1
11
2
9 10 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
E
8 New
New 140 Nm (14.0 m • kg, 100 ft • lb)
T.
R.
New
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.

T.
T.
R.
R.

Rider seat/Right side cover 4-1.
Drain.
page 3-11.
Drain.
Clutch release cylinder Refer to “CLUTCH” on page 5-53.
1 Oil pipe 2 1
2 Oil pipe 4 1
3 Transfer gear case cover 1
4 Transfer gear case gasket 1
5 Dowel pin 2
6 Transfer gear oil pump assembly 1
7 Dowel pin 2
5-86
TRANSFER GEAR CASE
Removing the middle driven shaft
3 18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
(5)
8 Nm (0.8 m • kg, 5.8 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)

T.
R.
(7)
LT New
LS
13 5
New
5
New
7
LS
7 4 New
12
6 New 1
11
2
9 10 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
E
8 New
New 140 Nm (14.0 m • kg, 100 ft • lb)
T.
R.
New
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.

T.
T.
R.
R.

8 Oil strainer 1
9 Gasket 1
11 Primary chain 1
12 Middle drive gear 1
13 Middle driven shaft 1
dure.
5-87
TRANSFER GEAR CASE
Disassembling the transfer gear oil pump
4
5
7
E 3
2
1
(6)
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.
R.

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 1
cedure.
5-88
TRANSFER GEAR CASE
Removing the transfer gear case

6 (8)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New 8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
3 LS 7
LT
LS 1
4
2
New
New
LT 5
LS
New 70 Nm (7.0 m • kg, 50 ft • lb)
T.
R.
10
LS
9
E
E
New
LS
(4)
50 Nm (5.0 m • kg, 36 ft • Ib)
T.
R.

Disconnect.
Horn 2 connector Refer to “ENGINE REMOVAL” on page 5-1.
Battery box 4-1.
Sub-fuel tank Refer to “FUEL TANK” on page 6-1.
1 Oil tank breather hose 1 Disconnect.
2 Speed sensor 1
3 Oil tank damper 1
4 Dipstick 1
5 Dipstick joint 1
6 Drive pulley case 1
7 Dowel pin 2
8 Spacer 1
9 Transfer gear case 1
10 Dowel pin 2
dure.
5-89
TRANSFER GEAR CASE
Disassembling the oil tank
7 28 Nm (2.8 m • kg, 20 ft • Ib)
T.
R.
4
6
1
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LS
LT
LT
New
New
5
(15)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
43 Nm (4.3 m • kg, 31 ft • Ib)

T.
R.
3 New

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
cedure.
5-90
TRANSFER GEAR CASE
EAS25470
2. Check:
REMOVING THE MIDDLE DRIVEN SHAFT
• Primary chain
NOTE: Damage/stiffness → Replace the primary
Loosen the middle drive gear nut before remove chain, middle drive gear and middle driven
the drive pulley. shaft as a set.
• Right rider footrest assembly CHECKING THE OIL STRAINER

Refer to “ENGINE REMOVAL” on page 5-1. 1. Check:
2. Loosen: • Oil strainer
• Middle drive gear nut “1” Damage → Replace.
NOTE: Contaminants → Clean with engine oil.
When loosening the middle drive gear nut, press EAS25500
down on the brake pedal so the middle drive CHECKING THE TRANSFER GEAR OIL
gear does not move. PUMP
1. Check:
• Transfer gear oil pump housing
• Transfer gear oil pump cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
1 • Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
3. Remove: Out of specification → Replace the transfer
• Primary chain “1”
gear oil pump.
• Middle drive gear “2”
• Middle driven shaft “3”
NOTE:
Remove the primary chain, middle drive gear
and middle driven shaft at the same time.
1
3
2
EAS25480
CHECKING THE MIDDLE DRIVE

1. Check:
• Middle drive gear
• Middle driven gear
Damage/wear → Replace the middle drive
gear, middle driven shaft and primary chain 1. Transfer gear oil pump inner rotor
as a set. 2. Transfer gear oil pump outer rotor
3. Transfer gear oil pump housing
5-91
TRANSFER GEAR CASE
• Transfer gear oil pump cover “7”

Inner-rotor-to-outer-rotor-tip NOTE:
clearance
Less than 0.12 mm (0.0047 in) When installing the inner rotor, align the pin in
Limit the oil pump shaft with the groove in the inner ro-
0.20 mm (0.0079 in) tor.
Outer-rotor-to-oil-pump-housing
clearance Oil pump housing screw
0.10–0.15 mm (0.0039–0.0059 in) 4 Nm (0.4 m·kg, 2.9 ft·lb)
T.
Limit
R.
0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-and- 1
outer-rotor clearance 4
0.04–0.09 mm (0.0016–0.0035 in) E
3
Limit 5 2
0.160 mm (0.0063 in) 6
7
3. Check:
• Transfer gear oil pump operation
Rough movement → Repeat steps (1) and (6)
(2) or replace the defective part(s).
3. Check:
• Transfer gear oil pump operation
Refer to “CHECKING THE TRANSFER
GEAR OIL PUMP” on page 5-91.
EAS25530
INSTALLING THE TRANSFER GEAR CASE

1. Install:
• Spacer “1”
NOTE:
Install the spacer with its groove “a” towards the
EAS25510
drive pulley.
CHECKING THE OIL PIPES
1. Check:
• Oil pipes 1
Damage → Replace.
EAS25520
ASSEMBLING THE TRANSFER GEAR OIL

PUMP
1. Lubricate:
• Transfer gear oil pump inner rotor
• Transfer gear oil pump outer rotor a
• Transfer gear oil pump shaft
(with the recommended lubricant) 2. Install:
• Middle driven shaft “1”
Recommended lubricant • Middle drive gear “2”
Engine oil • Primary chain “3”
(into the transfer gear case)
2. Install: • Drive pulley nut
• Transfer gear oil pump shaft “1” NOTE:
(to the transfer gear oil pump housing “2”)
• Install the primary chain with its blue link “a”
• Washer “3”
facing outward.
• Pin “4”
• Install the middle drive gear “2” with its cham-
• Transfer gear oil pump inner rotor “5”
fered side facing “b” the transfer gear case.
• Transfer gear oil pump outer rotor “6”
5-92
TRANSFER GEAR CASE
• Install the middle driven shaft, middle drive 4. Remove:

gear and primary chain at the same time. • Drive pulley nut
• Align the splines on the middle drive gear with
the splines on the drive axle.
• Temporarily install the drive pulley nut onto the
middle driven shaft.
a
3
1
2
3. Install:
• Middle drive gear nut “2” New
Middle drive gear nut

140 Nm (14.0 m·kg, 100 ft·lb)
T.
R.
NOTE:
• Lubricate the middle drive gear nut threads
and conical spring washer mating surfaces
with engine oil.
• Stake the middle drive gear nut “2” at a cutout
“b” in the drive axle.
a
2 New
5-93
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T.
LT
R. LT
LS 1 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New
New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(5) LS
T.
(4)
R.
LT
LT
New
3 9
3 (4) (4)
11
LS
(8)
LS
12
13 LT
4
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
9 New
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 5
T.
R.
New 6
7
8 (6)
LS New New LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
43 Nm (4.3 m • kg, 31 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Camshafts Refer to “CAMSHAFTS” on page 5-17.
Refer to “CYLINDERS AND PISTONS” on
Pistons page 5-48.
Left balancer driven gear housing Refer to “CLUTCH” on page 5-53.
Shift shaft Refer to “SHIFT SHAFT” on page 5-75.
Refer to “GENERATOR AND STARTER
Generator rotor CLUTCH” on page 5-77.
1 Neutral switch 1
2 Oil pipe 3 1
3 Oil strainer 2
5 Engine oil pump driven gear stopper 1
6 Engine oil pump driven gear 1
7 Oil baffle plate (left crankcase) 1
8 Left crankcase 1
9 Dowel pin 2
5-94
CRANKCASE
Separating the crankcase

10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T.
LT
R.
LT
LS 1 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New
New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(5) LS
T.
(4)
R.
LT
LT
New
3 9
3 (4) (4)
11
LS
(8)
LS
12
13 LT
4
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
9 New
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 5
T.
R.
New 6
7
8 (6)
LS New New LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
43 Nm (4.3 m • kg, 31 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

10 Joint pipe 1
11 Oil pipe 1 “R” mark
12 Oil pipe 1 “F” mark
13 Right crankcase 1
dure.
5-95
CRANKCASE
Removing the oil seals and bearings
LS
New 4
LS
5
E
LT
LT
New
2
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
5
New
1
LT
5
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)

3
T.
R.
LT
A 10 Nm (1.0 m • kg, 7.2 ft • lb)

5
3
T.
B 12 Nm (1.2 m • kg, 8.7 ft • lb)

R.
E
LT

Oil pump Refer to “OIL PUMP” on page 5-100.
Crankshaft Refer to “CRANKSHAFT” on page 5-106.
Transmission Refer to “TRANSMISSION” on page 5-112.
1 Oil baffle plate (right crankcase) 1
2 Bearing retainer 2
3 Bearing retainer 2
4 Oil seal 2
5 Bearing 4
dure.

5-96
CRANKCASE
EAS25570
DISASSEMBLING THE CRANKCASE

1. Remove:
• Crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
• Loosen the bolts in decreasing numerical order
(refer to the numbers in the illustration).
• M8 × 90 mm bolts: “1”, “2” EAS25580
• M8 × 65 mm bolt: “3” CHECKING THE CRANKCASE

• M6 × 100 mm bolts: “4”, “9”–“11” 1. Thoroughly wash the crankcase halves in a
• M6 × 80 mm bolt: “12” mild solvent.
• M6 × 70 mm bolts: “13”–“16” 2. Thoroughly clean all the gasket surfaces and
• M6 × 60 mm bolts: “5”–“8” crankcase mating surfaces.
• M6 × 35 mm bolts: “17”–“24” 3. Check:
• Crankcase
A
8 7 1 Cracks/damage → Replace.
6
3 • Oil delivery passages
2
5 Obstruction → Blow out with compressed air.
ET1D71005
CHECKING THE BEARINGS AND OIL SEAL

1. Check:
• Bearings
4 Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement → Replace.
B
13 • Oil seals
11 Damage/wear → Replace.
24 EAS25590
CHECKING THE OIL DELIVERY PIPE AND

12 OIL PIPE
23
1. Check:
17
22 • Oil delivery pipe
9 18 • Oil pipes
21 20 16 15 10 14 19
Damage → Replace.
A. Right crankcase Obstruction → Wash and blow out with com-
B. Left crankcase pressed air.
2. Remove: ET1D71038
• Left crankcase CHECKING THE OIL STRAINERS

ECA13900 1. Check:
CAUTION: • Oil strainers
Tap on one side of the crankcase with a soft- Damage → Replace.
face hammer. Tap only on reinforced por- Contaminants → Clean with solvent.
tions of the crankcase, not on the crankcase EAS25610
mating surfaces. Work slowly and carefully CHECKING THE ENGINE OIL PUMP DRIVEN
and make sure the crankcase halves sepa- GEAR
rate evenly. 1. Check:
• Engine oil pump driven gear
Chips/pitting/roughness/wear → Replace.
5-97
CRANKCASE
ET1D71034
INSTALLING THE BEARING RETAINERS 1

1. Install: 2
• Bearing retainers “1”
NOTE:
3
threads of the bearing retainer bolts.
4
• Stake the bearing retainer bolts “2”.
3
2 1
3. Install:
• Left crankcase
(onto the right crankcase)
NOTE:
Tap lightly on the left crankcase with a soft-face
1
hammer.
2
4. Install:
• Crankcase bolts (M6)
EAS25690
• Crankcase bolts (M8)
ASSEMBLING THE CRANKCASE
1. Apply: Crankcase bolt (M6)
• Sealant T.
R. 10 Nm (1.0 m·kg, 7.2 ft·lb)
(onto the crankcase mating surfaces) Crankcase bolt (M8)
24 Nm (2.4 m·kg, 17 ft·lb)
Yamaha bond No. 1215
90890-85505 NOTE:
• Lubricate the bolt threads with engine oil.
NOTE:
• Tighten each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern.
Do not allow any sealant to come into contact
• Tighten the bolts in numerical order (refer to
with the oil gallery.
the numbers in the illustration).
• M8 × 90 mm bolts: “1”, “2”
• M8 × 65 mm bolt: “3”
• M6 × 100 mm bolts: “4”, “9”–“11”
• M6 × 80 mm bolt: “12”
• M6 × 70 mm bolts: “13”–“16”
• M6 × 60 mm bolts: “5”–“8”
• M6 × 35 mm bolts: “17”–“24”
2. Install:
• Oil pipe (“F” mark) “1”
• Oil pipe (“R” mark) “2”
• Dowel pins “3”
• Joint pipe “4”
5-98
CRANKCASE
A
8 7 6 1
3 2
5
B
11 13
24
12
23
17
22
9 18
21 20 16 15 10 14 19
A. Right crankcase
B. Left crankcase
5. Apply:
• Engine oil
(onto the crankshaft pin bearings and oil de-
livery holes)
6. Check:
• Crankshaft and transmission operation
5-99
OIL PUMP
EAS24910
OIL PUMP
Removing the oil pump
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
1

Separate.
Crankcase Refer to “CRANKCASE” on page 5-94.
1 Oil pump assembly 1
dure.
5-100
OIL PUMP
Disassembling the oil pump
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
3
2
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
E
12
15
16
18 17
11
4
19 New
24
E
7
10 E
New 20
22 9
New 21 23
13
14 7
8

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 Oil scavenging pump inner rotor 2 1
11 Pin 1
12 Oil pump housing cover 2 1
13 Relief valve spring 1
14 Relief valve 1
15 Oil feed pump outer rotor 1
16 Oil feed pump inner rotor 1
17 Pin 1
5-101
OIL PUMP
Disassembling the oil pump
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
3
2
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
E
12
15
16
18 17
11
4
19 New
24
E
7
10 E
New 20
22 9
New 21 23
13
14 7
8

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
cedure.
5-102
OIL PUMP
EAS24960
3. Check:
CHECKING THE OIL PUMP
• Oil pump operation
1. Check:
Rough movement → Repeat steps (1) and
• Oil pump housing
(2) or replace the defective part(s).
• 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-outer-
rotor clearance “c”
Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip EAS24970
clearance CHECKING THE RELIEF VALVE

Less than 0.12 mm (0.0047 in) 1. Check:
Limit • Relief valve body
0.20 mm (0.0079 in) • Relief valve
Oil-pump-housing-to-inner-and- • Relief valve spring
outer-rotor clearance Damage/wear → Replace the defective
0.06–0.13 mm (0.0024–0.0051 in) part(s).
Limit
0.20 mm (0.0079 in) ET1D71035
Outer-rotor-to-oil-pump-housing CHECKING THE BALL SPRING AND RELIEF

clearance VALVE SPRING
0.09–0.19 mm (0.0035–0.0075 in) 1. Measure:
Limit • Ball spring free length
0.26 mm (0.0102 in) • Relief valve spring free length
part(s).
Ball spring
Free length
34.70 mm (1.37 in)
Limit
32.97 mm (1.30 in)
Relief valve spring
Free length
28.95 mm (1.14 in)
Limit
27.50 mm (1.08 in)
1. Inner rotor
2. Outer rotor a. Free length
3. Oil pump housing
5-103
OIL PUMP
2. Measure: • Oil pump shaft

• Ball spring force (with the recommended lubricant)
• Relief valve spring force
Out of specification → Replace the defective Recommended lubricant
part(s). Engine oil
Ball spring 2. Install:

Installed compression spring • Oil pump housing 2 “1”
force • Ball guide “2”
2.23 N (0.60 lb) (0.27 kgf) or less • Ball “3”
Installed length • Oil seal “4” New
29.4 mm (1.12 in)
Relief valve spring • Circlip “5” New
Installed compression spring • Oil seal “6” New
force • Oil pump shaft “7”
52.4 N (11.78 lb) (5.34 kgf) or
• Pin “8”
less
Installed length • Oil feed pump inner rotor “9”
16.8 mm (0.66 in) • Oil feed pump outer rotor “10”
• Relief valve “11”
• Relief valve spring “12”
• Oil pump housing cover 2 “13”

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
• Pin “14”
• Oil scavenging pump inner rotor 2 “15”
• Oil scavenging pump outer rotor 2 “16”
• Ball spring “17”
• Pins “18”
a. Spring force • Oil strainer “19”
b. Installed length • Oil pump housing 1 “20”
EAS24990
• Pin “21”
CHECKING THE OIL STRAINER • Oil scavenging pump inner rotor 1 “22”
1. Check: • Oil scavenging pump outer rotor 1 “23”
• Oil strainer “1” • Oil pump housing cover 1 “24”
Damage → Replace.
Contaminants → Clean with solvent. Oil pump housing cover 1 screw
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
NOTE:
When installing the inner rotor, align the pin in
the oil pump shaft with the groove in the inner ro-
tor.
EAS25000
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Inner rotor
• Outer rotor
5-104
OIL PUMP
20
22
23
24
19
13 E
10
9
78
14 21
6 New
1
E 18 E
15
New 5 16
3 2
New 4
12
11 18
17
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-103.
EAS25020
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly “1”
Oil pump assembly bolt

24 Nm (2.4 m·kg, 17 ft·lb)
T.
R.
ECA13890
CAUTION:
After tightening the bolts, make sure the oil
pump turns smoothly.
5-105
CRANKSHAFT
EAS25960
CRANKSHAFT
Removing the crankshaft

Separate.
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
dure.
5-106
CRANKSHAFT
EAS26010
REMOVING THE CONNECTING RODS

1. Remove:
• Connecting rod caps “1”
• Connecting rods
• Big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
3. Measure:
• Crankshaft-pin-to-big-end-bearing clearance
Out of specification → Replace the big end
bearings.
Journal oil clearance (using plas-

tigauge®)
0.030–0.062 mm (0.0012–0.0024
in)
EAS26090 The following procedure applies to all of the

CHECKING THE CRANKSHAFT AND connecting rods.
CONNECTING RODS ECA13930
1. Measure: CAUTION:
• Crankshaft runout Do not interchange the big end bearings and
Out of specification → Replace the crank- connecting rods. To obtain the correct
shaft. crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big
Runout limit C end bearings must be installed in their origi-
0.040 mm (0.0016 in) nal positions.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the big end bearings, crankshaft pins,
and the inside of the connecting rod halves.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing into
the connecting rod cap.
NOTE:
Align the projections “a” on the big end bearings
with the notches “b” in the connecting rod and
connecting rod cap.
2. Check:
• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces
Scratches/wear → Replace the crankshaft.
• Generator shaft drive gear “1”
Damage/wear → Replace the crankshaft.
c. Put a piece of Plastigauge® “1” on the crank-

shaft pin.
5-107
CRANKSHAFT
d. Assemble the connecting rod halves. h. Tighten the connecting rod bolts further to
NOTE: reach the specified angle 125–135°.
• Do not move the connecting rod or crankshaft
Connecting rod bolt (final)
until the clearance measurement has been Specified angle 125–135°
T.
completed.
R.
• Lubricate the bolts threads with molybdenum
disulfide grease.
• Make sure the projection “c” on the connecting
rod faces towards the left side of the crank-
shaft.
• Make sure the characters “d” on both the con-
necting rod and connecting rod cap are
aligned.
EW1D71011
WARNING
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.
EC1D71001
e. Tighten the connecting rod bolts. CAUTION:

EWA12890
• Do not use a torque wrench to tighten the
WARNING bolt to the specified angle.
• Replace the connecting rod bolts with new • Tighten the bolt until it is at the specified
ones. angle.
• Clean the connecting rod bolts.
i. Remove the connecting rod and big end
NOTE: bearings.
The tightening procedure of the connecting rod j. Measure the compressed Plastigauge®
bolts is angle controlled, therefore tighten the width “e” on the crankshaft pin.
bolts using the following procedure. If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select re-
f. Tighten the connecting rod bolts to the spec- placement big end bearings.
ified torque.
Connecting rod bolt (1st)

15 Nm (1.5 m·kg, 11 ft·lb)
T.
R.
g. Put a mark “1” on the connecting rod bolts “2”

and the connecting rod cap “3”.
5-108
CRANKSHAFT
For example, if the connecting rod “P1” and

the crankshaft web “P” numbers are “5” and
“2” respectively, then the bearing size for “P1”
is:
“P1” (connecting rod) - “P” (crankshaft)
=
5 - 2 = 3 (brown)
Bearing color code

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1.Blue 2.Black 3.Brown 4.Green
4. Select: 5.Yellow
• Big end bearings (“P1”–“P2”)
5. Measure:
NOTE: • Crankshaft journal diameter “a”
• The numbers “a” stamped into the crankshaft Out of specification → Replace the crank-
web and the numbers “b” on the connecting shaft.
rods are used to determine the replacement NOTE:
big end bearing sizes. Measure the diameter of each crankshaft journal
• “P1”–“P2” refer to the bearings shown in the at two places.
crankshaft illustration.
Crankshaft journal diameter
49.968–49.980 mm (1.9672–
P1 P2 1.9677 in)
a
6. Measure:
• Crankshaft journal bearing inside diameter
“a”
Out of specification → Replace the crank-
case assembly.
NOTE:
Measure the inside diameter of each crankshaft
journal bearing at two places.
Crankshaft journal bearing inside

diameter
50.010–50.030 mm (1.9689–
1.9697 in)
5-109
CRANKSHAFT
EAS26150
INSTALLING THE CONNECTING RODS

1. Lubricate:
• Bolt threads
Molybdenum disulfide grease
2. Lubricate:
• Crankshaft pins
• Big end bearings 4. Tighten:
• Connecting rod inner surface • Connecting rod bolts “1”
Engine oil
3. Install:
• Big end bearings
• Connecting rods
• Connecting rod caps
(onto the crankshaft pins)
NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA12890
• Align the projections “a” on the big end bear- WARNING
ings with the notches “b” in the connecting rods
• Replace the connecting rod bolts with new
and connecting rod caps.
ones.
• Be sure to reinstall each big end bearing in its
• Clean the connecting rod bolts.
original place.
• Make sure the projection “c” on the connecting NOTE:
rods face towards the left side of the crank- The tightening procedure of the connecting rod
shaft. bolts is angle controlled, therefore tighten the
• Make sure the characters “d” on both the con- bolts using the following procedure.
necting rod and connecting rod cap are
aligned. a. Tighten the connecting rod bolts with a torque
wrench.
Connecting rod bolt (1st)

15 Nm (1.5 m·kg, 11 ft·lb)
T.
R.
b. Put a mark “1” on the corner of the connecting

rod bolts “2” and the connecting rod “3”.
5-110
CRANKSHAFT
NOTE:
• Make sure that the generator shaft drive gear
teeth and generator shaft driven gear teeth
mesh correctly.
• Align the punch mark “a” on the generator shaft
driven gear with the punch mark “b” on the gen-
erator shaft drive gear.
• Align the right connecting rod with the front cyl-
inder sleeve hole.
c. Tighten the connecting rod bolts further to
reach the specified angle 125–135°.
Connecting rod bolt (final)

Specified angle 125–135°
T.
R.
2 b a
EW1D71011
WARNING
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.
EC1D71001
CAUTION:
• Do not use a torque wrench to tighten the
bolt to the specified angle.
• Tighten the bolt until it is at the specified
angle.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS26210
INSTALLING THE CRANKSHAFT

ASSEMBLY
1. Install:
• Generator shaft “1”
• Crankshaft assembly “2”
ECA13970
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
5-111
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
New
LS E
2
7
3
1
3
M
E
4
E
1
M
6

Separate.
1 Shift fork guide bar 2
2 Shift drum assembly 1
3 Shift fork 1 2
4 Shift fork 2 1
5 Drive axle assembly 1
6 Main axle assembly 1
7 Spacer 1
dure.
5-112
TRANSMISSION
Disassembling the main axle assembly

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 gear 1
12 Collar 1
13 Main axle/1st pinion gear 1
cedure.
5-113
TRANSMISSION
Disassembling the drive axle assembly

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 gear 1
13 Circlip 1
14 Toothed washer 1
15 2nd wheel gear 1
16 Collar 1
5-114
TRANSMISSION
Disassembling the drive axle assembly

17 Drive axle 1
cedure.
5-115
TRANSMISSION
EAS26260 EAS26270
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY

The following procedure applies to all of the shift 1. Check:
forks. • Shift drum groove
1. Check: Damage/scratches/wear → Replace the shift
• Shift fork cam follower “1” drum assembly.
• Shift fork pawl “2” • Shift drum segment “1”
Bends/damage/scoring/wear → Replace the Damage/wear → Replace the shift drum as-
shift fork. sembly.
• Shift drum bearing “2”
Damage/pitting → Replace the shift drum as-
sembly.
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace. EAS26300
EWA12840
CHECKING THE TRANSMISSION
WARNING 1. Measure:
Do not attempt to straighten a bent shift fork • Main axle runout
guide bar. (with a centering device and dial gauge “1”)
Out of specification → Replace the main axle.
Main axle runout limit

0.08 mm (0.0032 in)
3. Check:
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set. 2. Measure:
• Drive axle runout
(with a centering device and dial gauge “1”)
Out of specification → Replace the drive axle.
Drive axle runout limit

0.08 mm (0.0032 in)
5-116
TRANSMISSION
1 2
2 New
3. Check:
• Transmission gears b
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
2. Install:
• Toothed lock washer retainer “1”
• Toothed lock washer “2”
NOTE:
• With the toothed lock washer retainer “1” in the
groove “a” in the axle, align the projection “c”
4. Check: on the retainer with an axle spline “b”, and then
• Transmission gear engagement install the toothed lock washer “2”.
(each pinion gear to its respective wheel • Be sure to align the projection on the toothed
gear) lock washer that is between the alignment
Incorrect → Reassemble the transmission marks “e” with the alignment mark “d” on the
axle assemblies. retainer.
5. Check:
• Transmission gear movement 1 d b e
2
Rough movement → Replace the defective c
part(s). b
6. Check:
• Circlips a
Bends/damage/looseness → Replace. c
2
ET1D71006
ASSEMBLING THE MAIN AXLE AND DRIVE 1 e

AXLE
• Toothed washer “1” INSTALLING THE SHIFT FORKS AND SHIFT

DRUM ASSEMBLY
• Circlip “2” New
1. Install:
NOTE:
• Shift forks 1 “1”
• Be sure the circlip sharp-edged corner “a” is • Shift fork 2 “2”
positioned opposite side to the toothed washer • Shift drum assembly “3”
and gear. (for main axle) • Shift fork guide bars “4”
• Install the circlip so that both ends “b” rest on
the sides of a spline “c” with both axles aligned.
5-117
TRANSMISSION
NOTE:
The embossed marks “1D7” on the shift forks
should face towards the left side of the engine.
2
4 3
2. Check:
• Transmission
NOTE:
• Apply engine oil to each gear and bearing thor-
oughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-118
TRANSMISSION
5-119
FUEL SYSTEM
FUEL TANK..................................................................................................... 6-1

REMOVING THE FUEL TANK ..................................................................6-4
REMOVING THE FUEL PUMP .................................................................6-4
CHECKING THE FUEL PUMP BODY.......................................................6-5
CHECKING THE FUEL PUMP OPERATION............................................6-5
INSTALLING THE FUEL PUMP................................................................6-5
INSTALLING THE FUEL TANK.................................................................6-5
THROTTLE BODIES .......................................................................................6-7

REMOVING THE FUEL HOSE ...............................................................6-15
CHECKING THE INJECTORS ................................................................6-15
CHECKING THE THROTTLE BODIES...................................................6-15
CHECKING THE ROLLOVER VALVES.................................................. 6-15
CHECKING THE PRESSURE REGULATOR .........................................6-15
CHECKING THE PRESSURE REGULATOR OPERATION ................... 6-15
ADJUSTING THE THROTTLE POSITION SENSOR..............................6-16
INSTALLING THE FUEL PIPE ................................................................6-16
INSTALLING THE FUEL HOSE ..............................................................6-17
ISC (IDLE SPEED CONTROL) UNIT ............................................................ 6-18

CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM ................... 6-19
6
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
3 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1
7
5
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
A
16 Nm (1.6 m • kg, 11 ft • Ib) 9 10

8
T.
R.
(4) B
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib) 4

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Rider seat/Rider seat bracket 4-1.
1 Meter cover 1
Disconnect.
2 Meter assembly coupler 3 For XV19S(C)/ XV19M(C)/ XV19CTS(C)/
XV19CTM(C)
Disconnect.
3 Meter assembly coupler 2 For XV19CS(C)/ XV19C(C)
4 Fuel sender coupler 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Air vent hose (fuel pump to fuel hose joint) 1 Disconnect.
7 Fuel tank 1
8 Fuel tank bracket (rear side) 1
9 Fuel tank bracket (front side) 1
6-1
FUEL TANK
Removing the fuel tank
3 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1
7
5
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
A
16 Nm (1.6 m • kg, 11 ft • Ib) 9 10

8
T.
R.
(4) B
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib) 4

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

10 Fuel sender 1
dure.

6-2
FUEL TANK
Removing the fuel pump and sub-fuel tank
4
5 Nm (0.5 m • kg, 3.6 ft • Ib)
T.
R.
5
3 New
1
(6)
2 6
7
8 New
(3)
(3)
9
(3)
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

1 Fuel pump coupler 1 Disconnect.
2 Fuel hose connector cover 1
4 Air vent hose (fuel pump to fuel hose joint) 1
Fuel return hose (fuel return pipe to sub-fuel
5 1 Disconnect.
tank)
6 Fuel pump bracket 1
7 Fuel pump gasket 1
8 Fuel pump 1
9 Sub-fuel tank 1
dure.
6-3
FUEL TANK
EAS26630
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.
2. Remove:
• Fuel tank
EC1D71021
CAUTION:
Although the fuel has been removed from 1
1
the fuel tank, be careful when removing the
fuel hoses, since there may be fuel remain-
ing in them. d. Disconnect the fuel hose (fuel hose joint to
fuel pump) “1” and air vent hose (fuel pump to
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ fuel hose joint) “2”.
a. Remove the fuel hose joint caps “1”.
NOTE:
NOTE:
Before removing the hoses, place a few rags in
After removing the fuel hose joint caps, clean the
the area under where they will be removed.
projection on each cap so that no foreign mate-
rial will enter the fuel lines.
2
1
1
e. Install the fuel hose joint cap “1” and rubber

plug “2”.
b. Lubricate the O-ring “1” with the recommend-
ed silicone lubricant “2”. NOTE:
Insert the projection on the fuel hose joint cap
Recommended lubricant completely into the pipe of the fuel hose joint and
Silicone protectant and lubri- insert the rubber plug into the end of the fuel
cant hose (fuel hose joint to fuel pump).
ACC-SLCNS-PR-AY
NOTE:
Spray the silicone lubricant in the areas shown in 1
2
the illustration.
1
f. Remove the fuel tank.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS26640
REMOVING THE FUEL PUMP

1. Remove:
c. Turn the screws “1” clockwise. • Fuel hose connector cover
NOTE: 2. Disconnect:
Turn the screws until they stop. • Fuel outlet hose
6-4
FUEL TANK
EC1D71022
• Install the fuel pump as shown in the illustra-
CAUTION: tion.
• Be sure to disconnect the fuel outlet hose • Align the projection “a” on the fuel pump with
by hand. Do not forcefully disconnect the the slot in the fuel pump bracket.
hose with tools. • Tighten the fuel pump bolts in the proper tight-
• Although the fuel has been removed from ening sequence as shown.
the fuel tank be careful when removing the
fuel hoses, since there may be fuel remain-
ing in them.
NOTE:
• Remove the fuel hose manually without using
any tools.
• Before removing the hoses, place a few rags in
3. Remove:
• Fuel pump 2. Connect:
ECA14720
CAUTION: • Fuel outlet hose

3. Install:
• Do not drop the fuel pump or give it a
• Fuel hose connector cover “1”
strong shock. EC1D71023
• Do not touch the base section of the fuel CAUTION:

sender. When installing the fuel outlet hose, make
sure that it is securely connected, and that
EAS26670
CHECKING THE FUEL PUMP BODY the fuel hose connector cover is installed
1. Check: correctly, otherwise the fuel outlet hose will
• Fuel pump body not be properly installed.
Obstruction → Clean. NOTE:
Cracks/damage → Replace fuel pump as- • Install the fuel outlet hose connector securely
sembly. onto the sub fuel tank until a distinct “click” is
2. Check: heard, and then make sure that it does not
• Diaphragms and gaskets come loose.
Tears/fatigue/cracks → Replace fuel pump • Install the holder “a” of the fuel hose connector
assembly. cover, and then install the holder “b”. After in-
EAS26690 stalling the fuel hose connector cover, make
CHECKING THE FUEL PUMP OPERATION sure that it is installed securely.
1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PUMP” on 1
page 7-90. a
EAS26710
INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump
Fuel pump bolt b

5 Nm (0.5 m·kg, 3.6 ft·lb)
T.
R.
ET1D71025
NOTE:
INSTALLING THE FUEL TANK
1. Install:
• Do not damage the installation surfaces of the
• Fuel tank
sub-fuel tank when installing the fuel pump. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Always use a new fuel pump gasket. a. Install the fuel tank.
6-5
FUEL TANK
b. Remove the fuel hose joint caps.

c. Connect the fuel hose (fuel hose joint to fuel
pump) and air vent hose (fuel pump to fuel
hose joint).
d. Turn the screws “1” counterclockwise.
NOTE:
Turn the screws until they contact the clips “a”.
1
1
a
a
e. Install the fuel hose joint caps.

NOTE:
Install the fuel hose joint caps completely onto
the fuel hose joints.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Meter assembly couplers
• Fuel sender coupler
NOTE:
Make sure that the couplers are positioned as
shown in the illustration in the following order
from left to right: fuel sender coupler “1”, 6-pin
black meter assembly coupler “2”, 6-pin white
meter assembly coupler “3”, and 3-pin black
meter assembly coupler “4”.
4
3
6-6
THROTTLE BODIES
EAS26970
THROTTLE BODIES
Removing the rollover valves (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
4
7
7 1
6
5 7
10
9 2
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

For California only
2 Horn 1 1 For California only
3 Fuel tank breather hose 1
4 Canister purge hose 1 For California only
5 Rollover valve 1 1
7 Rollover valve hose 4
8 Fuel tank breather/overflow hose 1 For California only
9 Fuel tank breather/overflow hose 1 Except for California
10 Canister 1 For California only
11 Canister breather hose 1 For California only
dure.
6-7
THROTTLE BODIES
Removing the rollover valves (for XV19CS/ XV19C)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
5
R.
5
3
5 4
5
5
7
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

Air filter case
4-1.
1 Pressure regulator cover 1
6 Fuel tank breather/overflow pipe 1
7 Fuel tank breather/overflow hose 1
dure.
6-8
THROTTLE BODIES
Removing the rollover valves (for california only) (for XV19CSC/ XV19CC)
4
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
8
R.
8
6
8 7
8
8
10
1
11
12 2
10
7 Nm (0.7 m • kg, 5.1 ft • Ib) 3
T.
R.
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Air filter case
4-1.
2 Horn 1 1
5 Canister purge hose 1
9 Fuel tank breather/overflow pipe 1
10 Canister hose 2
11 Canister 1
12 Canister breather hose 1
dure.
6-9
THROTTLE BODIES
Removing the pressure regulator (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
8 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
7
2
7 Nm (0.7 m • kg, 5.1 ft • Ib) 6

T.
R.
3 9
4

Fuel hose (intake manifold assembly to pres-
2 1
sure regulator)
3 Air filter case breather hose 1 1
5 Hose clamp 1
6 Pressure regulator 1
7 Fuel return hose 1
8 Fuel return pipe 1
9 Pressure regulator bracket 1
dure.
6-10
THROTTLE BODIES
Removing the left ignition coils and pressure regulator (for XV19CS(C)/ XV19C(C))
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4
LT 16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
6
8
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7
7 Nm (0.7 m kg, 5.1 ft Ib)
• •
T.
R.
9 3
2
LT
1 LT
10 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

Rollover valves Refer to “THROTTLE BODIES” on page 6-7.
4 Fuel return pipe 1
5 1 Disconnect.
sure regulator)
6 Pressure regulator bracket 1
9 Fuel return hose 1
10 Pressure regulator 1
dure.
6-11
THROTTLE BODIES
Removing the throttle bodies
5 3 Nm (0.3 m • kg, 2.2 ft • Ib)
T.
R.
7
3
2
6
8
6
3 Nm (0.3 m • kg, 2.2 ft • Ib)
T.
R.

Air filter case 4-1.
Cylinder-#1 ignition coil cover Refer to “ENGINE REMOVAL” on page 5-1.
1 Throttle position sensor coupler 1 Disconnect.
2 Cylinder-#1 intake air pressure sensor hose 1
3 Cylinder-#2 intake air pressure sensor hose 1
4 Canister purge hose 1 For California only
5 Throttle cable 2 Disconnect.
6 Throttle body joint clamp screw 2 Loosen.
EC1D71013
CAUTION:
7 Throttle body 1
The throttle bodies should not be disas-
sembled.
8 Throttle position sensor 1

dure.
6-12
THROTTLE BODIES
Removing the intake manifolds
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
(2) 6
New 8
2
(2)
4 1
7
New 8
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

1 Engine temperature sensor coupler 1 Disconnect.
2 Sub-wire harness 2 coupler 2 Disconnect.
4 1
sure regulator)
Cylinder-#2 ISC (idle speed control) unit outlet
5 1 Disconnect.
hose
6 1 Disconnect.
hose
7 Intake manifold assembly 1
8 Gasket 2
dure.
6-13
THROTTLE BODIES
Disassembling the intake manifolds
30 Nm (3.0 m • kg, 22 ft • Ib)
.
R.
New
New
5 Nm (0.5 m • kg, 3.6 ft • Ib)
T.
R.
4
5
New
New 7 New
New
2
1 New
New
7
5 Nm (0.5 m • kg, 3.6 ft • Ib)

T.
R.

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
cedure.
6-14
THROTTLE BODIES
ET1D71026
b. Blow out all of the passages with compressed
REMOVING THE FUEL HOSE
air.
1. Disconnect:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel hose (intake manifold assembly to pres-
sure regulator) ET1D71007
EC1D71014 CHECKING THE ROLLOVER VALVES

CAUTION: 1. Check:
Although the fuel has been removed from • Rollover valve 1 “1”
the fuel tank be careful when removing the • Rollover valve 2 “2”
fuel hose, since there may be fuel remaining Damage/faulty → Replace.
in it. NOTE:
• Check that air flows smoothly only in the direc-
NOTE:
tion of the arrow shown in the illustration.
• To remove the fuel hose from the fuel pipe or • The rollover valves must be in an upright posi-
pressure regulator, slide the fuel hose connection when checking the airflow.
tor cover “1” on the end of the hose in the direc-
tion of the arrow shown, press the two buttons
“2” on the sides of the connector, and then re-
move the hose.
• Remove the fuel hose manually without using 1
2
any tools.
• Before removing the hoses, place a few rags in
EAS27000
CHECKING THE PRESSURE REGULATOR

1. Check:
• Pressure regulator
Damage → Replace.
1 2 EAS27010
CHECKING THE PRESSURE REGULATOR

OPERATION
EAS26980
1. Check:
CHECKING THE INJECTORS
• Pressure regulator operation
1. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Injectors a. Remove the pressure regulator cover.
Damage → Replace. Refer to “THROTTLE BODIES” on page 6-7.
EAS26990 b. Disconnect the fuel hose “1” from the pres-
CHECKING THE THROTTLE BODIES sure regulator “2”.
1. Check: c. Connect the fuel pressure adapter “3” be-
• Throttle bodies tween the fuel hose “1” and pressure regula-
Cracks/damage → Replace the throttle bod- tor “2”.
ies as a set. d. Connect the pressure gauge “4” to the fuel
2. Check: pressure adapter “3”.
• Fuel passages e. Connect the vacuum/pressure pump gauge
Obstructions → Clean. set “5” to the pressure regulator.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle bodies in a petroleum-
based solvent.
Do not use any caustic carburetor cleaning
solution.
6-15
THROTTLE BODIES
EAS27030
Vacuum/pressure pump gauge ADJUSTING THE THROTTLE POSITION

set SENSOR
90890-06756 1. Check:
Mityvac brake bleeding tool • Throttle position sensor
YS-42423 Refer to “CHECKING THE THROTTLE PO-
Pressure gauge SITION SENSOR” on page 7-89.
90890-03153 2. Adjust:
YU-03153 • Throttle position sensor angle
Fuel pressure adapter ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
90890-03176 a. Connect the throttle position sensor coupler
YM-03176 to the throttle position sensor.
b. Connect the digital circuit tester to the throttle
position sensor.
• Positive tester probe
yellow terminal “1”
• Negative tester probe
black terminal “2”
1 Digital circuit tester

90890-03174
2 Model 88 Multimeter with ta-
chometer
YU-A1927
1 c. Turn the main switch to “ON”.
4 d. Measure the throttle position sensor output
voltage.
5 e. Adjust the throttle position sensor angle so
that the output voltage is within the specified
2 range.
3
Output voltage (at idle)
f. Start the engine. 0.63–0.73 V
g. Measure the fuel pressure.
f. After adjusting the throttle position sensor an-
Fuel pressure gle, tighten the throttle position sensor
392 kPa (3.92 kg/cm², 55.7 psi) screws “3”.
h. Use the vacuum/pressure pump gauge set to

adjust the fuel pressure in relation to the vac-
uum pressure as described below.
3
NOTE:
3
The vacuum pressure should not exceed 100
kPa (760 mmHg). 2
1
• Increase the vacuum pressure →
Fuel pressure is decreased
• Decrease the vacuum pressure → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Fuel pressure is increased
ET1D71008
Faulty → Replace the pressure regulator. INSTALLING THE FUEL PIPE

1. Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel pipe “1”
6-16
THROTTLE BODIES
Fuel pipe bolt

T.
R.
30 Nm (3.0 m·kg, 22 ft·lb)
NOTE:
Install the fuel pipe “1” so that it contacts the pro-
jections “a” on the injector joints.
1
a
ET1D71027
INSTALLING THE FUEL HOSE

1. Connect:
• Fuel hose (intake manifold assembly to pres-
sure regulator)
EC1D71015
CAUTION:
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
NOTE:
• Install the fuel hose securely onto the fuel pipe
or pressure regulator until a distinct “click” is
heard.
• To install the fuel hose onto the fuel pipe or
pressure regulator, slide the fuel hose connec-
tor cover “1” on the end of the hose in the direc-
tion of the arrow shown.
6-17
ISC (IDLE SPEED CONTROL) UNIT
ET1D71009

Removing the ISC (idle speed control) unit
T.
T.
R.
R.
2
1
7
9
(4) 3
3 4
7 Nm (0.7 m • kg, 5.1 ft • Ib) 5 4

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

Front cylinder head Refer to “CYLINDER HEADS” on page 5-36.
3 2
hose
4 2
hose
5 ISC (idle speed control) unit inlet hose 1
6 Cylinder-#2 left ignition coil 1 XV19CTM(C)
7 Cylinder-#2 right ignition coil 1 XV19CTM(C)
8 ISC (idle speed control) unit 1
9 ISC (idle speed control) unit bracket 1
dure.
6-18
ET1D71010
CHECKING THE ISC (IDLE SPEED

CONTROL) SYSTEM
1. Check:
• Hoses
Loose connections → Connect properly.
6-19
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 7-1

CIRCUIT DIAGRAM .................................................................................. 7-1
ENGINE STOPPING DUE TO SIDESTAND OPERATION.......................7-3
TROUBLESHOOTING ..............................................................................7-4
ELECTRIC STARTING SYSTEM .................................................................... 7-7

CIRCUIT DIAGRAM .................................................................................. 7-7
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 7-9
TROUBLESHOOTING ............................................................................7-11
CHARGING SYSTEM....................................................................................7-13
CIRCUIT DIAGRAM ................................................................................ 7-13
LIGHTING SYSTEM ......................................................................................7-17

CIRCUIT DIAGRAM ................................................................................ 7-17
SIGNALING SYSTEM ...................................................................................7-21

CIRCUIT DIAGRAM ................................................................................ 7-21
FUEL INJECTION SYSTEM..........................................................................7-27

CIRCUIT DIAGRAM ................................................................................ 7-27
ECU SELF-DIAGNOSTIC FUNCTION....................................................7-29
SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 7-30
TROUBLESHOOTING METHOD............................................................ 7-32
DIAGNOSTIC MODE .............................................................................. 7-33
TROUBLESHOOTING DETAILS ............................................................ 7-40
FUEL PUMP SYSTEM...................................................................................7-63

CIRCUIT DIAGRAM ................................................................................ 7-63
TROUBLESHOOTING ............................................................................7-65 7
ELECTRICAL COMPONENTS...................................................................... 7-67
CHECKING THE SWITCHES .................................................................7-71
CHECKING THE BULBS AND BULB SOCKETS ................................... 7-74
CHECKING THE FUSES ........................................................................7-75
CHECKING AND CHARGING THE BATTERY....................................... 7-76
CHECKING THE RELAYS ...................................................................... 7-79
CHECKING THE TURN SIGNAL RELAY ............................................... 7-80
CHECKING THE DIODES....................................................................... 7-81
CHECKING THE IGNITION SPARK GAP............................................... 7-83
CHECKING THE SPARK PLUG CAPS...................................................7-83
CHECKING THE IGNITION COILS......................................................... 7-84
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 7-84
CHECKING THE LEAN ANGLE SENSOR.............................................. 7-85
CHECKING THE STARTER MOTOR OPERATION ...............................7-85
CHECKING THE STATOR COIL ............................................................ 7-85
CHECKING THE RECTIFIER/REGULATOR ..........................................7-86
CHECKING THE HORNS ....................................................................... 7-86
CHECKING THE ENGINE TEMPERATURE SENSOR .......................... 7-87
CHECKING THE FUEL SENDER (FUEL TANK) .................................... 7-88
CHECKING THE FUEL SENDER (FUEL PUMP) ................................... 7-88
CHECKING THE FUEL LEVEL WARNING LIGHT .................................7-89
CHECKING THE SPEED SENSOR ........................................................ 7-89
CHECKING THE THROTTLE POSITION SENSOR ...............................7-89
CHECKING THE FUEL PUMP................................................................7-90
CHECKING THE EXUP SERVO MOTOR............................................... 7-90
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 7-91
CHECKING THE AIR TEMPERATURE SENSOR ..................................7-91
EAS27110
EAS27090
A
R/W
B/R
L R/W B/R
L R/W R Sb/W Ch Dg Dg Ch
Y L B B L Y
R L R/W L/W R/L
L L/R R/Y L/G L/Y Sb B/Y Sb/W
Gy/W B/R B G Gy/R O
B/G B Gy Y/B Gy/R O B/R WIRE HARNESS SUB-WIRE-HARNESS1
L/G
O
Br/W P/Y W/R L Gy/G L/B R/L R/W R/B B/Br P/L B/L R/G B/Y
R/L G/W Y/G Br P/W L/R L/W W/Y Gy R/B B/Br Y/L Y Br/L W/G B
B B
R/Y L/W R/L Sb L/G
B/Y L/Y L/R (BLUE)
G/W B B/R
Sb
R/L B Gy G Br Br G Gy
O W W B B W W
B Sb B
B L/G
CIRCUIT DIAGRAM
B/R
B B
B (BLUE) C
B/R WIRE HARNESS SUB-WIRE-HARNESS2
B O B/R
O
Gy/R Gy/R C Gy/R Gy/R
Gy/R Gy/R C Gy/R C
IGNITION SYSTEM
W R/W B/R Gy/R B/R Gy/R Gy/R B/R Gy/R

W R R R L/B
W Gy Gy/R (BLACK) (BLACK)
Gy R/G R/G D R/G R/G
B R R
P/L P/L D P/L P/L
R W/G W/G D W/G W/G WIRE HARNESS SUB-WIRE-HARNESS3
(BLACK) B/L
WW W L W/Y W L L Br/L Br/L D Br/L Br/L
B
Gy B/L B Gy B/L B W/Y W/Y
(GRAY)
R/B
R R/G B/L W/G R/B R/G R/B D
R B B E B
R B/L Br/L R/B P/L
R R/Y L L Y B Y Y E Y Y R/B
R/B
L L E L L
R R (BLACK) D D W/G R/B R/G R/G R/B W/G
Br/L Br L/W R/B Br/L R/B P/L P/L R/B Br/L
ON
R/B
OFF L (BLACK) (BLACK)
R R L
L/Y L/B L/B L/Y B/G B/G
(GRAY) B/L P/W L P/W
(GRAY) B/R B/R WIRE HARNESS SUB-WIRE-HARNESS4
B/L P/W
R/Y (BLACK) P/Y
Br/L L/B L L W/R B/L
R/Y L W/R W/R B/G B/R
L/Y
B B B/L P/Y L P/Y B/L
B/L Br/W Br/W (BLACK) E
B B/L
B B (BLACK) Br Y/L
Br/W B/L
Gy/G W G
(BLACK) R/B Gy/W Y L L Y
R/B (GRAY) B B
B B B B Br Br B Br G W W B W
R/W R/W R/W R/W
R/Y R/L
WIRE HARNESS SUB-WIRE-HARNESS2
Br B L/R G G B G
Gy Gy B Gy W Gy
Y/G Y/B
(BLACK)
B/Y (DARK GRAY)
Gy W W B W
L
Y/G
L Y/G B/L
B/Br B
B/L
B/Br B Gy/G B/L
R/L Gy/W
7-1
R R/B Gy/W R/L
B B
Gy/G B/L
W L
(BLACK)
Br/L L
B G
Br/L Br Br
G
Br Y/B Br
W/Y B/W G B
R R/Y R/Y G/L Br P
Br/W Br (BLACK) P
R/Y B Sb/W
G/L Br/W Y/R W/Y Y/R B
Br Br/L Br/L R/W Br Y/B B B
R/G
Y/L Y L Dg Dg L Y
G/W R/W Sb Ch Ch Sb/W R/W
G
R/W
Br Br G/Y Y/L G/W R/G R/G G/W Y/L
Br Y R/W B/R L/W G/L G B B G
L/Y B/Y G/L Br/W Y/R P G/Y
(BLACK)
(BLACK)
B R/L G Y Y G
B B Y Br B B G/B
G/L G/L G/Y G/Y
(BLACK)
(BLUE) (BLUE) G/B G/B
B/R R/W R/W B/R B (L) PUSH
B Y L/B G/L B/Y L/Y B B (BLACK)
Br B Y Br G/L L/B B N (BLACK)
G/B G/Y G/Y G/B (R)
(BLACK) (BLACK)
(GRAY) (GRAY)
W/B L/W L/W W/B
B P P B
Y/R Y/R
(BLACK) (BLACK) (GRAY) (GRAY)
L
W/B L/B Dg Ch Ch Dg
L/B Br/W Br/W
Y Ch
(GRAY)
(GRAY)
A
Y Y G Ch Dg B G/B Dg
L/B B
Y
L A L
B B L/B
L Y
L B
Ch A Ch
Y G
Dg A Dg
Ch Dg Ch L Dg L
B Y
(BLACK) Y B
(BLACK)
B G
Ch L L Ch Dg L L Dg
B B B B
B B
(GRAY) (GRAY) (BLACK) (BLACK)
B B B
B
B A B B B
IGNITION SYSTEM
IGNITION SYSTEM
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
32.Spark plug
68.Engine stop switch
77.Ignition fuse
81.ECU fuse (for XV19S(C)/ XV19M(C)/
7-2
IGNITION SYSTEM
ET1D71043
ENGINE STOPPING DUE TO SIDESTAND OPERATION

When the engine is running and the transmission is in gear, the engine will stop if the sidestand is
moved down. This is because the electric current from the ignition coils does not flow to the ECU when
both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from
producing a spark. However, the engine continues to run under the following conditions:
• The transmission is in gear (the neutral switch circuit is open) and the sidestand is up (the sidestand
switch circuit is closed).
• The transmission is in neutral (the neutral switch circuit is closed) and the sidestand is down (the sid-
estand switch circuit is open).
5
10
8
6
11 9
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Engine stop switch
6. Ignition coil
7. Spark plug
9. Sidestand switch
10. Relay unit (diode)
11. Neutral switch
7-3
IGNITION SYSTEM
EAS27140
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Rider seat
2. Tool kit tray
3. Rider seat bracket assembly
4. Fuel tank
5. Air filter case
6. Headlight assembly
7. Exhaust pipes
8. Front cylinder
1. Check the fuses. NG →

(Main, ignition and ECU (for
XV19S(C)/ XV19M(C)/
Replace the fuse(s).
XV19CTS(C)/ XV19CTM(C)))
Refer to “CHECKING THE FUS-
ES” on page 7-75.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 7-76.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug(s).
PLUGS” on page 3-9.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 7-83.
NG ↓
5. Check the spark plug caps. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap(s).
PLUG CAPS” on page 7-83.
OK ↓
6. Check the ignition coils. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil(s).
TION COILS” on page 7-84.
OK ↓
7-4
IGNITION SYSTEM
7. Check the crankshaft position sen- NG →

sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 7-84.
OK ↓
8. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-71.
OK ↓
9. Check the engine stop switch. NG →
The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the right handlebar switch.
OK ↓
10.Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
11.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
12.Check the relay unit (diode). NG →
Refer to “CHECKING THE DI- Replace the relay unit.
ODES” on page 7-81.
OK ↓
13.Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 7-85.
OK ↓
14.Check the entire ignition system NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem wiring.
page 7-1.
OK ↓
Replace the ECU.
7-5
IGNITION SYSTEM
7-6
EAS27170
EAS27160
A
R/W
B/R
L R/W B/R
Y L B B L Y
R L R/W L/W R/L
Gy/W B/R B G Gy/R O
L/G
O
B B
R/Y L/W R/L Sb L/G
B/Y L/Y L/R (BLUE)
G/W B B/R
Sb
O W W B B W W
B Sb B
B L/G
CIRCUIT DIAGRAM
B/R
B B
B (BLUE) C
B O B/R
O
Gy/R Gy/R C Gy/R C

W R R R L/B
B R R
P/L P/L D P/L P/L
(BLACK) B/L
B
(GRAY)
R/B
R B B E B
R B/L Br/L R/B P/L
R/B
L L E L L
ON
R/B
R R L
B/L P/W
R/Y (BLACK) P/Y
L/Y
B B/L
B B (BLACK) Br Y/L
Br/W B/L
ELECTRIC STARTING SYSTEM
Gy/G W G
R/B (GRAY) B B
R/W R/W R/W R/W
R/Y R/L
Br B L/R G G B G
Gy Gy B Gy W Gy
Y/G Y/B
(BLACK)
B/Y (DARK GRAY)
Gy W W B W
L
Y/G
L Y/G B/L
B/Br B
B/L
B/Br B Gy/G B/L
R/L Gy/W
7-7
R R/B Gy/W R/L
B B
Gy/G B/L
W L
(BLACK)
Br/L L
B G
Br/L Br Br
G
Br Y/B Br
W/Y B/W G B
R R/Y R/Y G/L Br P
Br/W Br (BLACK) P
R/Y B Sb/W
R/G
Y/L Y L Dg Dg L Y
G
R/W
(BLACK)
(BLACK)
B R/L Y Br B B G Y Y G
B B G/B
G/L G/L G/Y G/Y
(BLACK)
B Y B B (BLACK) (BLACK)
Br B Y Br L/B G/L G/L L/B B/Y L/Y B N
G/B G/Y G/Y G/B (R)
(BLACK) (BLACK)
(GRAY) (GRAY)
W/B L/W L/W W/B
B P P B
Y/R Y/R
(BLACK) (BLACK)
(GRAY) (GRAY)
L
W/B L/B Dg Ch Ch Dg
L/B Br/W Br/W
Y Ch
(GRAY)
(GRAY)
A
L/B B
Y
L A L
B B L/B
L Y
L B
Ch A Ch
Y G
Dg A Dg
Ch Dg Ch L Dg L
B Y
(BLACK) Y B
(BLACK)
B G
Ch L L Ch Dg L L Dg
B B B B
B B
B B B
B
B A B B B
3. Main switch
4. Main fuse
6. Battery
8. Starter relay
9. Starter motor
10.Diode 1 (for XV19S(C)/ XV19M(C)/
11.Relay unit
12.Starting circuit cut-off relay
14.Neutral switch
16.Sidestand switch
54.Clutch switch
69.Start switch
77.Ignition fuse
7-8
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 in neutral (the neutral switch circuit is closed).
• The clutch lever is pulled to the handlebar (the clutch switch circuit is closed) and the sidestand is up
(the sidestand switch circuit is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay stays open so current cannot reach
the starter motor. When at least one of the above conditions has been met, the starting circuit cut-off
relay is closed and the engine can be started by pushing the start switch “ ”.
14
13
2
17
3
4
15
5
6
8
8
9 a
8
10 11 12
b
16
7-9
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
6. Diode 2 (for XV19S(C)/ XV19M(C)/
7. Relay unit (starting circuit cut-off relay)
8. Relay unit (diode)
9. Clutch switch
10. Sidestand switch
11. Neutral switch
12. Start switch
13. Starter relay
14. Starter motor
15. ECU fuse (for XV19S(C)/ XV19M(C)/
7-10
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
1. Rider seat
2. Tool kit tray

(Main, ignition and ECU (for
XV19S(C)/ XV19M(C)/
Replace the fuse(s).
XV19CTS(C)/ XV19CTM(C)))
ES” on page 7-75.
OK ↓
page 7-76.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
7-85.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-84.
OK ↓
5. Check the relay unit (starting circuit NG →
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 7-79.
OK ↓
6. Check the relay unit (diode). NG →
OK ↓
7. Check the diode 1. (for XV19S(C)/ NG →
XV19M(C)/ XV19CTS(C)/
XV19CTM(C)) Replace the diode 1.
Refer to “CHECKING THE DI-
OK ↓
7-11

OK ↓
9. Check the starter relay. NG →
Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
10.Check the main switch. NG →
OK ↓
11.Check the engine stop switch. NG →
OK ↓
12.Check the neutral switch. NG →
OK ↓
13.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
14.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
15.Check the start switch. NG →
The start switch is faulty. Replace the right
handlebar switch.
OK ↓
16.Check the entire starting system NG →
wiring. Properly connect or repair the starting sys-
page 7-7.
OK ↓
The starting system circuit is OK.
7-12
EAS27210
EAS27200
R/W
L R/W B/R B/R
L R/W R Sb/W
R L R/W L/W R/L

Gy/W B/R B
B/G B
L/G
Br/W P/Y W/R

R/L G/W Y/G Br
CIRCUIT DIAGRAM
B B
R/Y L/W R/L Sb L/G
B/Y L/Y L/R (BLUE)
G/W B
Sb
R/L B
B Sb B
B L/G
B B
B (BLUE)
CHARGING SYSTEM
W R/W
W R R R L/B
W Gy
Gy
B R R
R
(BLACK) B/L
WW W L W/Y W L L
B
(GRAY)
R R/G B/L
R B B E B
R B/L
R R/Y L L Y B Y Y E Y Y
L L E L L
R R (BLACK)
Br/L Br ON L/W
OFF L
R R
7-13
L/Y L/B L/B L/Y L
(GRAY)
B/L P/W
R/Y (BLACK) P/Y
Br/L L/B
R/Y L
L/Y
B B B/L P/Y L P/Y
B B/L B/L Br/W Br/W
B B (BLACK) Br
Br/W B/L
(BLACK) R/B
R/B
R/W R/W R/W R/W B B B B Br Br B Br
R/Y R/L
Br B L/R
Y/G
(BLACK)
B/Y
L
Y/G
L Y/G B/L
B/L
R R/B
Br/L L
Br/L Br Br
Br Y/B
W/Y
R R/Y R/Y G/L
R/Y Br/W Br
Br Br/L Br/L R/W Br Y/B B
CHARGING SYSTEM
CHARGING SYSTEM
1. AC magneto
2. Rectifier/regulator
4. Main fuse
6. Battery
7-14
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
NOTE:
1. Rider seat
2. Rectifier/regulator cover
3. Lead cover
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 7-75.
OK ↓
page 7-76.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil.
COIL” on page 7-85.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 7-86.
OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 7-13.
OK ↓
The charging system circuit is OK.
7-15
CHARGING SYSTEM
7-16
EAS27250
EAS27240
A
R/W
B/R
L R/W B/R
Y L B B L Y
R L R/W L/W R/L
Gy/W B/R B G Gy/R O
L/G
O
B B
R/Y L/W R/L Sb L/G
B/Y L/Y L/R (BLUE)
G/W B B/R
Sb
O W W B B W W
B Sb B
B L/G
CIRCUIT DIAGRAM
B/R
B B
B (BLUE) C
B O B/R
O
Gy/R Gy/R C Gy/R C
LIGHTING SYSTEM

W R R R L/B
B R R
P/L P/L D P/L P/L
(BLACK) B/L
B
(GRAY)
R/B
R B B E B
R B/L Br/L R/B P/L
R/B
L L E L L
ON
R/B
R R L
B/L P/W
R/Y (BLACK) P/Y
L/Y
B B/L
B B (BLACK) Br Y/L
Br/W B/L
Gy/G W G
R/B (GRAY) B B
R/W R/W R/W R/W
R/Y R/L
Br B L/R G G B G
Gy Gy B Gy W Gy
Y/G Y/B
(BLACK)
B/Y (DARK GRAY)
Gy W W B W
L
Y/G
L Y/G B/L
B/Br B
B/L
B/Br B Gy/G B/L
R/L Gy/W
7-17
R R/B Gy/W R/L
B B
Gy/G B/L
W L
(BLACK)
Br/L L
B G
Br/L Br Br
G
Br Y/B Br
W/Y B/W G B
R R/Y R/Y G/L Br P
Br/W Br (BLACK) P
R/Y B Sb/W
R/G
Y/L Y L Dg Dg L Y
G
R/W
(BLACK)
(BLACK)
B R/L B B G Y Y G
B B Y Br G/B
G/L G/L G/Y G/Y
(BLACK)
B Y B B (BLACK)
Br B Y Br L/B G/L G/L L/B B/Y L/Y B N (BLACK)
G/B G/Y G/Y G/B (R)
(BLACK) (BLACK)
(GRAY) (GRAY)
W/B L/W L/W W/B
B P P B
Y/R Y/R
L
W/B L/B Dg Ch Ch Dg
L/B Br/W Br/W
Y Ch
(GRAY)
(GRAY)
A
L/B B
Y
L A L
B B L/B
L Y
L B
Ch A Ch
Y G
Dg A Dg
Ch Dg Ch L Dg L
B Y
(BLACK) Y B
(BLACK)
B G
Ch L L Ch Dg L L Dg
B B B B
B B
B B B
B
B A B B B
LIGHTING SYSTEM
LIGHTING SYSTEM
3. Main switch
4. Main fuse
6. Battery
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 beam)
70.Accessory light switch
71.Accessory light (OPTION)
72.Tail/brake light
73.License plate light
78.Headlight fuse
79.Signaling system fuse
80.Taillight fuse
7-18
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light,
taillight, license light, position light, meter light or accessory light (OPTION).
NOTE:
1. Rider seat
2. Tool kit tray
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
7-74.
OK ↓
(Main, headlight, signaling system,
taillight and ECU (for XV19S(C)/
XV19M(C)/ XV19CTS(C)/ Replace the fuse(s).
XV19CTM(C)))
ES” on page 7-75.
OK ↓
page 7-76.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
6. Check the accessory light switch. NG →
The accessory light switch is faulty. Re-
place the right handlebar switch.
OK ↓
7. Check the headlight relay. NG →
Refer to “CHECKING THE RE- Replace the headlight relay.
OK ↓
7-19
LIGHTING SYSTEM
8. Check the entire lighting system NG →

wiring. Properly connect or repair the lighting sys-
page 7-17.
OK ↓
The lighting system circuit is OK.
7-20
EAS27280
EAS27270
A
R/W
B/R
L R/W B/R
Y L B B L Y
R L R/W L/W R/L
Gy/W B/R B G Gy/R O
L/G
O
B B
R/Y L/W R/L Sb L/G
B/Y L/Y L/R (BLUE)
G/W B B/R
Sb
O W W B B W W
B Sb B
B L/G
CIRCUIT DIAGRAM
B/R
B B
B (BLUE) C
B O B/R
O
Gy/R Gy/R C Gy/R C

W R R R L/B
SIGNALING SYSTEM

B R R
P/L P/L D P/L P/L
(BLACK) B/L
B
(GRAY)
R/B
R B B E B
R B/L Br/L R/B P/L
R/B
L L E L L
ON
R/B
R R L
B/L P/W
R/Y (BLACK) P/Y
L/Y
B B/L
B B (BLACK) Br Y/L
Br/W B/L
Gy/G W G
R/B (GRAY) B B
R/W R/W R/W R/W
R/Y R/L
Br B L/R G G B G
Gy Gy B Gy W Gy
Y/G Y/B
(BLACK)
B/Y (DARK GRAY)
Gy W W B W
L
Y/G
L Y/G B/L
B/Br B
B/L
B/Br B Gy/G B/L
R/L Gy/W
7-21
R R/B Gy/W R/L
B B
Gy/G B/L
W L
(BLACK)
Br/L L
B G
Br/L Br Br
G
Br Y/B Br
W/Y B/W G B
R R/Y R/Y G/L Br P
Br/W Br (BLACK) P
R/Y B Sb/W
R/G
Y/L Y L Dg Dg L Y
G
R/W
(BLACK)
(BLACK)
B R/L G Y Y G
B B Y Br B B G/B
G/L G/L G/Y G/Y
(BLACK)
B Y B B (BLACK)
Br B Y Br L/B G/L G/L L/B B/Y L/Y B N (BLACK)
G/B G/Y G/Y G/B (R)
(BLACK) (BLACK)
(GRAY) (GRAY)
W/B L/W L/W W/B
B P P B
Y/R Y/R
L
W/B L/B Dg Ch Ch Dg
L/B Br/W Br/W
Y Ch
(GRAY)
(GRAY)
A
L/B B
Y
L A L
B B L/B
L Y
L B
Ch A Ch
Y G
Dg A Dg
Ch Dg Ch L Dg L
B Y
(BLACK) Y B
(BLACK)
B G
Ch L L Ch Dg L L Dg
B B B B
B B
B B B
B
B A B B B
SIGNALING SYSTEM
SIGNALING SYSTEM
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
39.Neutral indicator light
40.Multi-function meter
43.Fuel level warning light
45.Left turn signal indicator light
46.Right turn signal indicator light
48.Fuel sender (fuel tank)
49.Horn 1
50.Horn 2
51.Turn signal relay
56.Turn signal switch
57.Horn switch
59.Front right turn signal/position light
60.Front left turn signal/position light
61.Rear right turn signal light
62.Rear left turn signal light
67.Front brake light switch
72.Tail/brake light
74.Rear brake light switch
77.Ignition fuse
7-22
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The fuel level gauge fails to operate.
• The speedometer fails to operate.
NOTE:
1. Rider seat
2. Tool kit tray
5. Fuel tank

(Main, backup, ignition, signaling
system and ECU (for XV19S(C)/
XV19M(C)/ XV19CTS(C)/ Replace the fuse(s).
XV19CTM(C)))
ES” on page 7-75.
OK ↓
page 7-76.
OK ↓
OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or repair the signaling
page 7-21.
OK ↓
Check the condition of each of the sig-
naling system’s circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

The horn fails to sound.
1. Check the horn switch. NG →
The horn switch is faulty. Replace the left
handlebar switch.
OK ↓
7-23
SIGNALING SYSTEM
2. Check the horns. NG →

Refer to “CHECKING THE Replace the horn(s).
HORNS” on page 7-86.
OK ↓
page 7-21.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 7-21.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the condition of each bulb NG →
and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
7-74.
OK ↓
2. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
3. Check the turn signal relay. NG →
Refer to “CHECKING THE TURN Replace the turn signal relay.
SIGNAL RELAY” on page 7-80.
OK ↓
7-24
SIGNALING SYSTEM

page 7-21.
OK ↓
This circuit is OK.
The neutral indicator light fails to come on.

1. Check the neutral switch. NG →
OK ↓
2. Check the relay unit (diode). NG →
OK ↓
page 7-21.
OK ↓
This circuit is OK.
The fuel level gauge fails to operate.

1. Check the fuel sender (fuel tank). NG →
Refer to “CHECKING THE FUEL
Replace the fuel sender.
SENDER (FUEL TANK)” on page
7-88.
OK ↓
page 7-21.
OK ↓
Replace the meter assembly.
The fuel level warning light fails to come on.

1. Check the fuel level warning light. NG →
Refer to “CHECKING THE FUEL Replace the meter assembly or fuel pump
LEVEL WARNING LIGHT” on page assembly.
7-89.
OK ↓
7-25
SIGNALING SYSTEM
2. Check the fuel sender (fuel pump). NG →

Refer to “CHECKING THE FUEL
Replace the fuel pump assembly.
SENDER (FUEL PUMP)” on page
7-88.
OK ↓
page 7-21.
OK ↓
This circuit is OK.
The speedometer fails to operate.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 7-89.
OK ↓
page 7-21.
OK ↓
Replace the meter assembly.
7-26
EAS27340
EAS27330
A
R/W
B/R
L R/W B/R
Y L B B L Y
R L R/W L/W R/L
Gy/W B/R B G Gy/R O
L/G
O
B B
R/Y L/W R/L Sb L/G
B/Y L/Y L/R (BLUE)
G/W B B/R
Sb
O W W B B W W
B Sb B
B L/G
CIRCUIT DIAGRAM
B/R
B B
B (BLUE) C
B O B/R
O
Gy/R Gy/R C Gy/R C

W R R R L/B
B R R
P/L P/L D P/L P/L
(BLACK) B/L
B
(GRAY)
R/B
R B B E B
R B/L Br/L R/B P/L
R/B
L L E L L
ON
R/B
FUEL INJECTION SYSTEM

R R L
B/L P/W
R/Y (BLACK) P/Y
L/Y
B B/L
B B (BLACK) Br Y/L
Br/W B/L
Gy/G W G
R/B (GRAY) B B
R/W R/W R/W R/W
R/Y R/L
Br B L/R G G B G
Gy Gy B Gy W Gy
Y/G Y/B
(BLACK)
B/Y (DARK GRAY)
Gy W W B W
L
Y/G
L Y/G B/L
B/Br B
B/L
B/Br B Gy/G B/L
R/L Gy/W
7-27
R R/B Gy/W R/L
B B
Gy/G B/L
W L
(BLACK)
Br/L L
B G
Br/L Br Br
G
Br Y/B Br
W/Y B/W G B
R R/Y R/Y G/L Br P
Br/W Br (BLACK) P
R/Y B Sb/W
R/G
Y/L Y L Dg Dg L Y
G
R/W
(BLACK)
(BLACK)
B R/L B B G Y Y G
B B Y Br G/B
G/L G/L G/Y G/Y
(BLACK)
B/R R/W R/W B/R B (L) PUSH (BLACK)
B Br B Y Br Y L/B G/L G/L L/B B/Y L/Y B B (BLACK)
B N
G/B G/Y G/Y G/B (R)
(BLACK) (BLACK)
(GRAY) (GRAY)
W/B L/W L/W W/B
B P P B
Y/R Y/R
L
W/B L/B Dg Ch Ch Dg
L/B Br/W Br/W
Y Ch
(GRAY)
(GRAY)
A
L/B B
Y
L A L
B B L/B
L Y
L B
Ch A Ch
Y G
Dg A Dg
Ch Dg Ch L Dg L
B Y
(BLACK) Y B
(BLACK)
B G
Ch L L Ch Dg L L Dg
B B B B
B B
B B B
B
B A B B B
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
16.Sidestand switch
17.Fuel pump
19.Crankshaft position sensor
20.Throttle position sensor
21.Cylinder-#1 intake air pressure sensor
22.Cylinder-#2 intake air pressure sensor
23.Lean angle sensor
24.Speed sensor
25.Air temperature sensor
26.Engine temperature sensor
32.Spark plug
33.ISC (idle speed control) unit
34.EXUP servo motor
35.Injector #2
36.Injector #1
37.O2 sensor
40.Multi-function meter
41.Reset switch
42.Engine trouble warning light
52.Headlight relay
55.Dimmer switch
58.Select switch
64.Headlight (high beam)
65.Headlight (low beam)
77.Ignition fuse
78.Headlight fuse
7-28
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is
operating normally. If this function detects a malfunction in the system, it immediately operates the en-
gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider
that a malfunction has occurred in the system. Once a malfunction has been detected, a fault code is
stored in the memory of the ECU.
• To inform the rider that the fuel injection system is not functioning, the engine trouble warning light
flashes when the start switch is being pushed to start the engine.
• If a malfunction is detected in the system by the self-diagnostic function, the ECU provides an appro-
priate substitute characteristic operation, and alerts the rider of the detected malfunction by illuminat-
ing the engine trouble warning light.
• After the engine has been stopped, the lowest fault code number appears on the odometer/tripme-
ter/fuel reserve tripmeter/clock LCD. Once a fault code has been displayed, it remains stored in the
memory of the ECU until it is deleted.
Engine trouble warning light indication and fuel injection system operation
Warning light indica- Fuel injection opera-
ECU operation Vehicle operation
tion tion
Warning provided
Flashing* when unable to start Operation stopped Cannot be operated
engine
Operated with substi-
tute characteristics in Can or cannot be oper-
Remains on Malfunction detected accordance with the ated depending on the
description of the mal- fault code
function
* The warning light flashes when any one of the conditions listed below is present and the start switch
is pushed:
Lean angle sensor
12: Crankshaft position sensor 41:
(open or short-circuit)
Blue/black ECU lead ECU internal malfunction
19: 50:
(broken or disconnected) (memory check error)
Lean angle sensor
30:
(latch up detected)
Checking the engine trouble warning light

The engine trouble warning light comes on for 1.4 seconds after the main switch has been turned to
“ON” and it comes on while the start switch is being pushed. If the warning light does not come on under
these conditions, the warning light (LED) may be defective.
a b
c d c
a. Main switch “OFF”

b. Main switch “ON”
c. Engine trouble warning light off
d. Engine trouble warning light on for 1.4
seconds
7-29
EAS27380
SELF-DIAGNOSTIC FUNCTION TABLE

If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi-
nates the engine trouble warning light and provides the engine with alternate operating instructions that
are appropriate for the type of malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that are
programmed for each sensor in order to provide the engine with alternate operating instructions that
enable the engine to continue to operate or stop operating, depending on the conditions.
Self-Diagnostic Function table

Able / un-
Fault Able / un-
Item Symptom able to
code No. able to start
drive
No normal signals are received
Crankshaft position
12 from the crankshaft position sen- Unable Unable
sensor
sor.
Cylinder-#1 intake air Cylinder-#1 intake air pressure
13 pressure sensor sensor: open or short circuit de- Able Able
(open or short circuit) tected.
14 pressure sensor sensor: hose system malfunction Able Able
(hose system) (clogged or detached hose).
Throttle position sen-
Throttle position sensor: open or
15 sor Able Able
short circuit detected.
(open or short circuit)
EXUP servo motor
EXUP servo motor circuit: open or
17 circuit Able Able
EXUP servo motor
18 EXUP servo motor is stuck. Able Able
(lock)
Blue/black ECU lead A break or disconnection of the
19 (broken or discon- blue/black lead of the ECU is de- Unable Unable
nected) tected.
Air temperature sen-
Air temperature sensor: open or
22 sor Able Able
No normal signal is received from
24 O2 sensor Able Able
the O2 sensor.
25 pressure sensor sensor: open or short circuit de- Able Able
(open or short circuit) tected.
26 pressure sensor sensor: hose system malfunction Able Able
(hose system) (clogged or detached hose).
Engine temperature
Engine temperature sensor: open
28 sensor Able Able
or short circuit detected.
Lean angle sensor
30 The vehicle has overturned. Unable Unable
(latch up detected)
7-30
Able / un-
Fault Able / un-
drive
Able Able
(depending (depending
Cylinder-#1 left or Malfunction detected in the prima-
on the on the
33 right ignition coil ry wire of the cylinder-#1 left or
number of number of
(faulty ignition) right ignition coil.
faulty cylin- faulty cylin-
ders) ders)
Able Able
on the on the
number of number of
ders) ders)
Able Able
on the on the
number of number of
ders) ders)
Able Able
on the on the
number of number of
ders) ders)
ISC valve (stuck fully Engine speed is high when the en-
37 Able Able
open) gine is idling.
Lean angle sensor Lean angle sensor: open or short
41 Unable Unable
(open or short circuit) circuit detected.
No normal signals are received
Speed sensor
from the speed sensor.
42 Able Able
Open or short circuit is detected in
Neutral switch
the neutral switch.
The ECU is unable to monitor the
Fuel system voltage battery voltage
43 Able Able
(monitoring voltage) (an open or short circuit in the line
to the ECU).
Error in writing the Error is detected while reading or
44 amount of CO adjust- writing on EEPROM (CO adjust- Able Able
ment on EEPROM ment value).
Vehicle system power
Power supply to the fuel injection
46 supply Able Able
system is not normal.
(Monitoring voltage)
Faulty ECU memory. (When this
ECU internal malfunc-
malfunction is detected in the
50 tion Unable Unable
ECU, the fault code number might
(memory check error)
not appear on the meter.)
7-31
Able / un-
Fault Able / un-
drive
Engine has been left idling. (The
ECU automatically stops the en-
70 Engine idling stop Able Able
gine after 20 minutes if it is left
idling.)
Communication error with the meter

Able / un-
Fault Able / un-
drive
No signals are received from the
Er-1 tion Unable Unable
ECU.
(output signal error)
No signals are received from the
ECU within the specified duration.
Data from the ECU cannot be re-
ceived correctly.
Non-registered data has been re-
ceived from the meter.
(input signal error)
EAS27400
2. Check and repair the probable cause of mal-
TROUBLESHOOTING METHOD
function.
The engine operation is not normal and the Fault code No. No fault code No.
engine trouble warning light comes on. Check and repair. Check and repair.
1. Check: Refer to “TROUBLE- Refer to “Self-Diag-
• Fault code number SHOOTING DE- nostic Function ta-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ TAILS” on page 7-40. ble”.
a. Check the fault code number displayed on Monitor the opera-
the meter. tion of the sensors
b. Identify the faulty system with the fault code. and actuators in the
Refer to “Self-Diagnostic Function table”. diagnostic mode. Re-
c. Identify the probable cause of the malfunc- fer to “Sensor opera-
tion. Refer to “Diagnostic code table”. tion table” and
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ “Actuator operation
table”.
3. Perform ECU reinstatement action.
Refer to “Reinstatement method” of table in
“TROUBLESHOOTING DETAILS”.
4. Turn the main switch to “OFF” and back to
“ON”, then check that no fault code number is
displayed.
NOTE:
If fault codes are displayed, repeat steps (1) to
(4) until no fault code number is displayed.
7-32
5. Erase the malfunction history in the diagnos- The engine operation is not normal but the
tic mode. Refer to “Sensor operation table engine trouble warning light does not come
(Diagnostic code No. 62)”. on.
NOTE: 1. Check the operation of following sensors and
Turning the main switch to “OFF” will not erase actuators in the Diagnostic mode. Refer to
the malfunction history. “Sensor operation table” and “Actuator oper-
ation table”.
01: Throttle position sensor (throttle angle)
30: Cylinder-#1 ignition coil
36: Injector #1
37: Injector #2
If a malfunction is detected in the sensors or
actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors
and actuators, check and repair inner parts of
the engine.
EAS27420
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the engine stop switch to “ ”.
2. Disconnect the wire harness coupler from the fuel pump.
3. Press and hold the “RESET” switch, turn the main switch to “ON”, and continue to press the switch
for 8 seconds or more.
“SELECT” “RESET”
NOTE:
• All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip
meter/clock displays.
• “dIAG” appears on the odometer/trip meter/fuel reserve trip meter/clock LCD.
4. Simultaneously press the “SELECT” and “RESET” switches for 2 seconds or more to activate the
diagnostic mode. The diagnostic code number “d01” appears on the clock LCD.
5. Set the engine stop switch to “ ”.
6. Select the diagnostic code number corresponding to the fault code number by pressing the “SE-
LECT” and “RESET” switches.
NOTE:
• To decrease the selected diagnostic code number, press the “RESET” switch. Press the “RESET”
switch for 1 second or longer to automatically decrease the diagnostic code numbers.
• To increase the selected diagnostic code number, press the “SELECT” switch. Press the “SELECT”
switch for 1 second or longer to automatically increase the diagnostic code numbers.
7-33
“d01 d70” “d70 d01”
7. Verify the operation of the sensor or actuator.

• Sensor operation
The data representing the operating conditions of the sensor appears on the odometer/trip meter/fu-
el reserve trip meter/clock LCD.
• Actuator operation
Set the engine stop switch to “ ” to operate the actuator.
NOTE:
If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again.
8. Turn the main switch to “OFF” to cancel the diagnostic mode.
Diagnostic code table

Fault
Diagnostic
code Symptom Probable cause of malfunction
code No.
No.
• Open or short circuit in wire harness.
• Defective crankshaft position sensor.
No normal signals are re-
• Malfunction in crankshaft position sensor
12 ceived from the crankshaft —
rotor.
position sensor.
• Malfunction in ECU.
• Improperly installed sensor.
Cylinder-#1 intake air pres-
• Defective cylinder-#1 intake air pressure
13 sure sensor: open or short 03
sensor.
circuit detected.
• Cylinder-#1 intake air pressure sensor hose
sure sensor: hose system
14 is detached, clogged, kinked, or pinched. 03
malfunction (clogged or de-
tached hose).
• Open or short circuit in wire sub lead.
Throttle position sensor: • Open or short circuit in wire harness.
15 open or short circuit detect- • Defective throttle position sensor. 01
ed. • Malfunction in ECU.
• Improperly installed throttle position sensor.
EXUP servo motor circuit: • Open or short circuit in wire harness.
17 open or short circuit detect- • Defective EXUP servo motor (potentiome- 53
ed. ter circuit).
18 EXUP servo motor is stuck. • Stuck EXUP servo motor (mechanism). 53
• Stuck EXUP servo motor (motor).
7-34
Fault
Diagnostic
code No.
No.
A break or disconnection of
• Open circuit in wire harness (ECU coupler).
19 the blue/black lead of the 20
ECU is detected.
Air temperature sensor:
• Defective air temperature sensor.
22 open or short circuit detect- 05
ed.
• Improperly installed air temperature sensor.
No normal signal is re- • Defective O2 sensor.
24 ceived from the O2 sensor. —
Cylinder-#2 intake air pres- • Open or short circuit in wire harness.
25 sure sensor: open or short • Defective cylinder-#2 intake air pressure 04
circuit detected. sensor.
• Cylinder-#2 intake air pressure sensor hose
sure sensor: hose system
26 is detached, clogged, kinked, or pinched. 04
malfunction (clogged or de-
tached hose).
Engine temperature sen- • Open or short circuit in wire harness.
28 sor: open or short circuit • Defective engine temperature sensor. 11
detected. • Malfunction in ECU.
The vehicle has over- • Overturned.
30 08
turned. • Malfunction in ECU.
Malfunction detected in the • Malfunction in cylinder-#1 left or right igni-
primary wire of the cylin- tion coil. 30
33
der-#1 left or right ignition • Malfunction in ECU. 32
coil. • Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the
• Malfunction in cylinder-#2 left or right igni-
primary wire of the cylin- 31
34 tion coil.
der-#2 left or right ignition 33
coil.
• Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the • Malfunction in cylinder-#1 left or right igni-
primary wire of the cylin- tion coil. 30
35
der-#1 left or right ignition • Malfunction in ECU. 32
coil. • Malfunction in a component of ignition cut-
off circuit system.
7-35
Fault
Diagnostic
code No.
No.
Malfunction detected in the
• Malfunction in cylinder-#2 left or right igni-
primary wire of the cylin- 31
36 tion coil.
der-#2 left or right ignition 33
coil.
• Malfunction in a component of ignition cut-
off circuit system.
• Open circuit in wire harness.
• Malfunction in throttle body.
• Malfunction in throttle cables.
• ISC valve is stuck fully open due to discon-
nected ISC unit hose or coupler. (High en-
Engine speed is high when gine idle speed is detected with the ISC
37 54
the engine is idling. valve stuck fully open even though signals
for the valve to close are continuously being
transmitted by the ECU.)
• ECU fuse is blown. (for XV19S(C)/
Lean angle sensor: open or
41 • Defective lean angle sensor. 08
• Open circuit in wire harness.
• Defective speed sensor.
No normal signals are re-
• Malfunction in vehicle speed sensor detect-
ceived from the speed sen-
ed. 07
42 sor.
• Defective neutral switch. 21
Open circuit is detected in
• Malfunction in the engine side of the neutral
the neutral switch.
switch.
The ECU is unable to moni-
tor the battery voltage (an • Open or short circuit in wire harness.
43 09
open or short circuit in the • Malfunction in ECU.
line to the ECU).
Error is detected while
• Malfunction in ECU. (The CO adjustment
reading or writing on EE-
44 value is not properly written on or read from 60
PROM (CO adjustment val-
the internal memory).
ue).
Power supply to the fuel in-
Malfunction in the charging system. Refer to
46 jection system is not nor- —
“CHARGING SYSTEM” on page 7-13.
mal.
Faulty ECU memory.
(When this malfunction is • Malfunction in ECU. (The program and data
50 detected in the ECU, the are not properly written on or read from the —
fault code number might internal memory.)
not appear on the meter.)
7-36
Fault
Diagnostic
code No.
No.
• Malfunction in meter.
No signals are received
Er-1 • Malfunction in ECU. —
from the ECU.
• Defective wire connection of the ECU cou-
pler.
No signals are received • Improper connection in wire harness.
Er-2 from the ECU within the • Malfunction in meter. —
specified duration. • Malfunction in ECU.
• Improper connection in wire harness.
Data from the ECU cannot
Er-3 • Malfunction in meter. —
be received correctly.
Non-registered data has • Improper connection in wire harness.
Er-4 been received from the • Malfunction in meter. —
meter. • Malfunction in ECU.
Sensor operation table

Diag-
nostic
Item Meter display Checking method
code
No.
01 Throttle angle
• Fully closed position 12–22 Check with throttle fully
closed.
• Fully opened position 87–107 Check with throttle fully
open.
03 Pressure difference Displays the cylinder-#1 in- Set the engine stop switch
(atmospheric pressure and take air pressure. to “ ”, and then push the
cylinder-#1 intake air pres- start switch “ ”. (If the dis-
sure) play value changes, the
performance is OK.)
04 Pressure difference Displays the cylinder-#2 in- Set the engine stop switch
(atmospheric pressure and take air pressure. to “ ”, and then push the
cylinder-#2 intake air pres- start switch “ ”. (If the dis-
sure) play value changes, the
performance is OK.)
05 Air temperature Displays the air temperature. Compare the actually mea-
sured air temperature with
the meter display value.
07 Vehicle speed pulse 0–999 Check that the number in-
creases when the rear
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
08 Lean angle sensor Remove the lean angle
• Upright 0.4–1.4 sensor and incline it more
than 65 degrees.
• Overturned 3.7–4.4
7-37
Diag-
nostic
code
No.
09 Fuel system voltage Approximately 12.0 Set the engine stop switch
(battery voltage) to “ ”, and then compare
with the actually measured
battery voltage. (If the bat-
tery voltage is lower, per-
form recharging.)
11 Engine temperature Displays the engine tempera- Compare the actually mea-
ture. sured engine temperature
with the meter display val-
ue.
20 Sidestand switch Set on/off the sidestand
• Stand retracted ON switch (with the transmis-
sion in gear).
• Stand extended OFF
21 Neutral switch Shift the transmission.
• Neutral ON
• In gear OFF
53 EXUP servo motor Displays the operating angle. —
Engine trouble warning light
comes on twice: once when
the EXUP valve is closing
and once when it is opening.
60 EEPROM fault code dis- —
play
• No history 00
• History exists 01 or 02 (Cylinder fault code)
• (If both cylinders are defec-
tive, the display alternates
every two seconds.)
61 Malfunction history code —
display
• No history 00
• History exists Fault codes 12-70
• (If more than one code
number is detected, the dis-
play alternates every two
seconds to show all the de-
tected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code
erasure
• No history 0 —
• History exists Up to 25 fault codes To erase the history, set the
engine stop switch to “ ”.
7-38
Diag-
nostic
code
No.
70 Control number 0–255 —
Actuator operation table

Diag-
nostic
Item Actuation Checking method
code
No.
Actuates the cylinder-#1 left
or right ignition coil five times Check the spark five times.
Cylinder-#1 left or right ig-
30 at one-second intervals. • Connect an ignition
nition coil
Illuminates the engine trou- checker.
ble warning light.
nition coil
ble warning light.
nition coil
ble warning light.
nition coil
ble warning light.
Actuates the injector #1 five
times at one-second inter-
Check the operating sound
36 Injector #1 vals.
of the injector #1 five times.
Illuminates the engine trou-
ble warning light.
Actuates the injector #2 five
times at one-second inter-
37 Injector #2 vals.
of the injector #2 five times.
ble warning light.
Actuates the fuel pump relay
five times at one-second in-
tervals.
ble warning light.
50 Fuel pump relay of the fuel pump relay five
(The engine trouble warning
times.
light is OFF when the relay is
ON, and the engine trouble
warning light is ON when the
relay is OFF).
7-39
Diag-
nostic
Item Actuation Checking method
code
No.
Actuates the headlight relay
for five cycles of five sec-
onds. (ON 2 seconds, OFF 3 Check the operating sound
52 Headlight relay seconds) of the headlight relay five
Illuminates the engine trou- times.
ble warning light and head-
light.
Actuates and fully closes the
ISC valve, then opens it to
the standby opening position
when the engine is started.
The ISC unit vibrates when
54 ISC valve This operation takes approxi-
the ISC valve operates.
mately 12 seconds until it is
completed.
ble warning light.
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 malfunctioning part has been completed, reset the meter display ac-
cording to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic
Function table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
MODE” on page 7-33.
7-40
Fault code No. 12 Symptom No normal signals are received from the crankshaft posi-
tion sensor.
Diagnostic code No. — —
Order Item/components and probable Check or maintenance job Reinstatement
cause method
1 Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the
tion sensor. engine.
2 Connections • Check the coupler for any pins
• Crankshaft position sensor coupler that may be pulled out.
• Main wire harness ECU coupler • Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler se-
curely.
3 Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between the crankshaft position
sensor coupler and ECU cou-
pler.
(gray–gray)
(black/blue–black/blue)
4 Defective crankshaft position sensor. • Replace if defective.
CRANKSHAFT POSITION
SENSOR” on page 7-84.
7-41
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
cause method
1 Connections • Check the coupler for any pins Turning the
• Cylinder-#1 intake air pressure sen- that may be pulled out. main switch to
sor coupler • Check the locking condition of “ON”.
• Main wire harness ECU coupler the coupler.
curely.
• Between cylinder-#1 intake air
pressure sensor coupler and
ECU coupler
(pink/white–pink/white)
(blue–blue)
3 Defective cylinder-#1 intake air pres- • Execute the diagnostic mode.
sure sensor. (Code No.03)
• Replace if defective.
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR” on page 7-91.
7-42
Fault code No. 14 Symptom Cylinder-#1 intake air pressure sensor: hose system mal-
function (clogged or detached hose).
cause method
1 Cylinder-#1 intake air pressure sensor • Check the cylinder-#1 intake air Starting the en-
hose pressure sensor hose condition. gine and oper-
• Repair or replace the sensor ating it at idle.
hose.
2 Cylinder-#1 intake air pressure sensor • Check and repair the connec-
malfunction at intermediate electrical tion.
potential. • Replace it if there is a malfunc-
tion.
• Cylinder-#1 intake air pressure sen- that may be pulled out.
sor coupler • Check the locking condition of
curely.
7-43
Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected.
Diagnostic code No. 01 Throttle position sensor
cause method
1 Installed condition of throttle position • Check for looseness or pinch- Turning the
sensor. ing. main switch to
• Check that the sensor is in- “ON”.
stalled in the specified position.
• Throttle position sensor coupler that may be pulled out.
• Sub-wire harness 2 coupler the coupler.
curely.
3 Open or short circuit in wire harness • Repair or replace if there is an
and/or sub lead. open or short circuit.
• Between throttle position sen-
sor coupler and ECU coupler
(blue–blue)
(yellow–yellow)
(black–black)
4 Throttle position sensor lead wire • Check for open circuit and re-
open circuit output voltage check. place the throttle position sen-
sor.
(black–yellow)
Open circuit Output voltage
item
Ground wire 5V
open circuit
Output wire 0V
open circuit
Power supply 0V
wire open cir-
cuit
5 Defective throttle position sensor. • Execute the diagnostic mode.
(Code No.01)
THROTTLE POSITION SEN-
7-44
Fault code No. 17 Symptom EXUP servo motor circuit: open or short circuit detected.
Diagnostic code No. 53 EXUP servo motor
cause method
• EXUP servo motor coupler that may be pulled out. main switch to
• Main wire harness ECU coupler • Check the locking condition of “ON”.
the coupler.
curely.
• Between servo motor coupler
and ECU coupler
(blue–blue)
(white/red–white/red)
3 Defective EXUP servo motor (potenti- • Execute the diagnostic mode.
ometer circuit). (Code No.53)
EXUP SERVO MOTOR” on
page 7-90.
Fault code No. 18 Symptom EXUP servo motor is stuck.

Diagnostic code No. 53 EXUP servo motor
cause method
• EXUP servo motor coupler that may be pulled out. main switch to
the coupler. It takes 120
• If there is a malfunction, repair it seconds at the
and connect the coupler se- maximum be-
curely. fore the origi-
2 Open or short circuit in wire harness. • Repair or replace if there is an nal state
open or short circuit. returns.
• Between the EXUP servo motor
coupler and the ECU coupler.
(black/green–black/green)
(black/red–black/red)
3 Defective EXUP servo motor. • Execute the diagnostic mode.
(Code No.53)
EXUP SERVO MOTOR” on
page 7-90.
4 Defective EXUP valve, pulley, cables. Replace if defective.
7-45
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
cause method
1 Connections • Execute the diagnostic mode. If the transmis-
• Main wire harness ECU coupler (Code No.20) sion is in gear,
• Check the coupler for any pins retracting the
that may be pulled out. sidestand.
• Check the locking condition of If the transmis-
the coupler. sion is in neu-
• If there is a malfunction, repair it tral,
and connect the coupler se- reconnecting
curely. the wiring.
• Between ECU and blue/black
lead
3 Defective sidestand switch. • Replace if defective.
Fault code No. 22 Symptom Air temperature sensor: open or short circuit detected.
Diagnostic code No. 05 Air temperature sensor
cause method
1 Installed condition of air temperature Check for looseness or pinching. Turning the
sensor. main switch to
2 Connections • Check the coupler for any pins “ON”.
• Air temperature sensor coupler that may be pulled out.
the coupler.
curely.
• Between air temperature sen-
sor coupler and ECU coupler
(brown/white–brown/white)
4 Defective air temperature sensor. • Execute the diagnostic mode.
(Code No.05)
Refer to “CHECKING THE AIR
TEMPERATURE SENSOR” on
page 7-91.
7-46
Fault code No. 24 Symptom No normal signal is received from the O2 sensor.

cause method
1 Installed state of O2 sensor. Check for looseness or pinching. Starting the en-
gine and oper-
2 Connections • Check the coupler for any pins ating it at idle.
• O2 sensor coupler that may be pulled out.
the coupler.
curely.
• Between O2 sensor coupler and
ECU coupler.
(gray/white–gray/white)
(red/blue–red/blue)
(gray/green–gray/green)
4 Check fuel pressure. • Refer to “THROTTLE BODIES”
on page 6-7.
5 Defective O2 sensor. • Replace if defective.
7-47
Fault code No. 25 Symptom Cylinder-#2 intake air pressure sensor: open or short cir-
cuit detected.
cause method
• Cylinder-#2 intake air pressure sen- that may be pulled out. main switch to
sor coupler • Check the locking condition of “ON”.
• Sub-wire harness 3 coupler • If there is a malfunction, repair it
curely.
• Between cylinder-#2 intake air
pressure sensor coupler and
ECU coupler
(pink/yellow–pink/yellow)
(blue–blue)
7-48
Fault code No. 26 Symptom Cylinder-#2 intake air pressure sensor: hose system mal-
function (clogged or detached hose).
cause method
1 Cylinder-#2 intake air pressure sensor • Check the cylinder-#2 intake air Starting the en-
hose pressure sensor hose condition. gine and oper-
• Repair or replace the sensor ating it at idle.
hose.
2 Cylinder-#2 intake air pressure sensor • Check and repair the connec-
malfunction at intermediate electrical tion.
potential. • Replace it if there is a malfunc-
tion.
• Cylinder-#2 intake air pressure sen- that may be pulled out.
sor coupler • Check the locking condition of
curely.
7-49
Fault code No. 28 Symptom Engine temperature sensor: open or short circuit detect-
ed.
Diagnostic code No. 11 Engine temperature sensor
cause method
1 Installed state of engine temperature Check for looseness or pinching. Turning the
sensor. main switch to
2 Connections • Check the coupler for any pins “ON”.
• Engine temperature sensor coupler that may be pulled out.
• Sub-wire harness 2 coupler the coupler.
curely.
• Between engine temperature
sensor coupler and ECU cou-
pler
(brown–brown)
(black–black)
4 Defective engine temperature sensor. • Execute the diagnostic mode.
(Code No.11)
Refer to “CHECKING THE EN-
GINE TEMPERATURE SEN-
Fault code No. 30 Symptom The vehicle has overturned.

Diagnostic code No. 08 Lean angle sensor
cause method
1 The vehicle has overturned. Raise the vehicle upright. Turning the
2 Installed condition of the lean angle Check for looseness or pinching. main switch to
sensor. “ON” (however,
the engine can-
3 Connections • Check the coupler for any pins not be restarted
• Lean angle sensor coupler that may be pulled out. unless the main
• Main wire harness ECU coupler • Check the locking condition of switch is first
the coupler. turned “OFF”).
curely.
4 Defective lean angle sensor. • Execute the diagnostic mode.
(Code No.08)
LEAN ANGLE SENSOR” on
page 7-85.
7-50
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
cause method
1 Connections • Check the connector and cou- Starting the en-
• Cylinder-#1 left or right ignition coil pler for any pins that may be gine and oper-
connector (primary coil side) pulled out. ating it at idle.
the connector and coupler.
curely.
• Between cylinder-#1 left or right
ignition coil connector and ECU
coupler/main wire harness.
(black/red–blue/red)
(orange–orange)
3 Defective cylinder-#1 left or right igni- • Execute the diagnostic mode.
tion coil. (Code No.30 or 32)
• Test the primary and secondary
coils for continuity.
Refer to “CHECKING THE IG-
NITION COILS” on page 7-84.
7-51
cause method
• Sub-wire harness 3 coupler the connector and coupler.
curely.
(gray/red–gray/red)
7-52
cause method
the connector and coupler.
curely.
(orange–orange)
7-53
cause method
• Sub-wire harness 3 coupler the connector and coupler.
curely.
(gray/red–gray/red)
7-54
Fault code No. 37 Symptom Engine speed is high when the engine is idling.
Diagnostic code No. 54 ISC valve
cause method
1 ECU fuse is blown. (for XV19S(C)/ • Check the ECU fuse. (for ISC valve re-
XV19M(C)/ XV19CTS(C)/ XV19S(C)/ XV19M(C)/ turns to its orig-
XV19CTM(C)) XV19CTS(C)/ XV19CTM(C)) inal position by
Refer to “CHECKING THE turning the
FUSES” on page 7-75. main switch to
2 Throttle valve does not fully close. • Check the throttle bodies. “ON” and back
Refer to “THROTTLE BODIES” to “OFF”.
on page 6-7. Reinstated if
• Check the throttle cables. the engine idle
Refer to “ADJUSTING THE speed is within
THROTTLE CABLE FREE specification af-
PLAY” on page 3-8. ter starting the
engine.
3 ISC valve is stuck fully open due to • Check that the ISC unit hose is
disconnected ISC unit hose or cou- not disconnected.
pler. (High engine idle speed is de- • Check that the ISC unit coupler
tected with the ISC valve stuck fully is not disconnected.
open even though signals for the valve • The ISC valve is stuck fully
to close are continuously being trans- open if it does not operate when
mitted by the ECU.) the main switch is turned “OFF”.
(Touch the ISC unit with your
hand and check if it is vibrating
to confirm if the ISC valve is op-
erating.)
4 ISC valve is not moving correctly. • Execute the diagnostic mode.
(Code No.54)
• After the ISC valve is fully
closed, it opens to the standby
opening position when the en-
gine is started. This operation
takes approximately 12 sec-
onds. Start the engine. If the er-
ror recurs, replace the throttle
body assembly.
7-55
Fault code No. 41 Symptom Lean angle sensor: open or short circuit detected.
Diagnostic code No. 08 Lean angle sensor
cause method
• Lean angle sensor coupler that may be pulled out. main switch to
the coupler.
curely.
2 Open or short circuit in lead wire. • Repair or replace if there is an
• Between lean angle sensor
coupler and ECU coupler.
(blue–blue)
(yellow/green–yellow/green)
3 Defective lean angle sensor. • Execute the diagnostic mode.
(Code No.08)
LEAN ANGLE SENSOR” on
page 7-85.
7-56
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
cause method
A-1 Connections • Check the coupler for any pins Starting the en-
• Speed sensor coupler that may be pulled out. gine, and acti-
• Main wire harness ECU coupler • Check the locking condition of vating the
the coupler. vehicle speed
• If there is a malfunction, repair it sensor by oper-
and connect the coupler se- ating the vehi-
curely. cle at 20 to 30
A-2 Open or short circuit in speed sensor • Repair or replace if there is an km/h.
lead. open or short circuit.
• Between speed sensor coupler
and ECU coupler.
(blue–blue)
(white/yellow–white/yellow)
A-3 Gear for detecting vehicle speed has • Replace if defective.
broken. Refer to “TRANSMISSION” on
page 5-112.
A-4 Defective speed sensor. • Execute the diagnostic mode.
(Code No.07)
SPEED SENSOR” on page
7-89.
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
cause method
B-1 Connections • Check the coupler for any pins Starting the en-
• Neutral switch coupler that may be pulled out. gine, and acti-
• Main wire harness ECU coupler • Check the locking condition of vating the
the coupler. vehicle speed
• If there is a malfunction, repair it sensor by oper-
and connect the coupler se- ating the vehi-
curely. cle at 20 to 30
B-2 Open circuit in neutral switch lead. • Repair or replace if there is an km/h.
open circuit.
• Between neutral switch coupler
and relay unit coupler (fuel
pump relay).
(sky blue–sky blue)
• Between relay unit coupler and
main switch.
(blue/yellow–blue/yellow)
• Between main switch and ECU
coupler.
(blue/black–blue/black)
B-3 Faulty shift drum (neutral detection ar- • Replace if defective.
ea). Refer to “TRANSMISSION” on
page 5-112.
B-4 Defective neutral switch. • Execute the diagnostic mode.
(Code No.21)
7-58
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
cause method
1 Connections • Check the coupler for any pins Starting the en-
• Relay unit coupler (fuel pump relay) that may be pulled out. gine and oper-
• Main wire harness ECU coupler • Check the locking condition of ating it at idle.
the coupler.
curely.
2 Open or short circuit in the wire har- • Repair or replace if there is an
ness. open or short circuit.
• Between relay unit coupler (fuel
pump relay) and ECU coupler.
(blue/red–blue/red)
(red/blue–red/blue)
pump relay) and battery termi-
nal.
(red–red)
pump relay) and diode 2 cou-
pler. (for XV19S(C)/ XV19M(C)/
(red/white–red/white)
• Between diode 2 coupler and
engine stop switch coupler. (for
XV19S(C)/ XV19M(C)/
(black/red–black/red)
3 Malfunction or open circuit in relay • Execute the diagnostic mode.
unit (fuel pump relay). (Code No. 09)
• If there is no malfunction with
the relay unit (fuel pump relay),
replace the ECU.
Fault code No. 44 Symptom Error is detected while reading or writing on EEPROM (CO
adjustment value).
Diagnostic code No. 60 EEPROM improper cylinder indication
cause method
1 Malfunction in ECU. • Execute the diagnostic mode. Turning the
(Code No. 60) main switch to
1. Check the faulty cylinder. (If “ON”.
multiple cylinders are defec-
tive, the number of the faulty
cylinders appears alternate-
ly at 2-second intervals.)
• Replace ECU if defective.
7-59
Fault code No. 46 Symptom Power supply to the fuel injection system is not normal.
cause method
1 Connections • Check the coupler for any pins Starting the en-
• Main wire harness ECU coupler that may be pulled out. gine and oper-
• Check the locking condition of ating it at idle.
the coupler.
curely.
2 Faulty battery. • Replace or charge the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-76.
3 Malfunction in rectifier/regulator • Replace if defective.
Refer to “CHARGING SYS-
TEM” on page 7-13.
• Between battery and main fuse
(red–red)
• Between main fuse and main
switch
(red–red)
• Between main switch and igni-
tion fuse
(brown/blue–brown/blue)
• Between ignition fuse and ECU
(red/white–red/white)
Fault code No. 50 Symptom Faulty ECU memory. (When this malfunction is detected in
the ECU, the fault code number might not appear on the
meter.)
cause method
1 Malfunction in ECU. Replace the ECU. Turning the
NOTE: main switch to
Do not perform this procedure “ON”.
with the main switch turned to
“ON”.
7-60
Fault code No. Er-1 Symptom No signals are received from the ECU.
cause method
• Main wire harness ECU coupler that may be pulled out. main switch to
• Main wire harness meter assembly • Check the locking condition of “ON”.
coupler the coupler.
curely.
• Between meter assembly cou-
pler and ECU coupler
(yellow/blue–yellow/blue)
3 Malfunction in meter assembly. Replace the meter assembly.
4 Malfunction in ECU. Replace the ECU.
Fault code No. Er-2 Symptom No signals are received from the ECU within the specified
duration.
cause method
curely.
7-61
Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.
cause method
curely.
Fault code No. Er-4 Symptom Non-registered data has been received from the meter.
cause method
curely.
7-62
EAS27560
EAS27550
A
R/W
B/R
L R/W B/R
Y L B B L Y
R L R/W L/W R/L
Gy/W B/R B G Gy/R O
L/G
O
B B
R/Y L/W R/L Sb L/G
B/Y L/Y L/R (BLUE)
G/W B B/R
Sb
O W W B B W W
CIRCUIT DIAGRAM
B Sb B
B L/G
B/R
B B
B (BLUE) C
B O B/R
O
Gy/R Gy/R C Gy/R C

W R R R L/B
FUEL PUMP SYSTEM

B R R
P/L P/L D P/L P/L
(BLACK) B/L
B
(GRAY)
R/B
R B B E B
R B/L Br/L R/B P/L
R/B
L L E L L
ON
R/B
R R L
B/L P/W
R/Y (BLACK) P/Y
L/Y
B B/L
B B (BLACK) Br Y/L
Br/W B/L
Gy/G W G
R/B (GRAY) B B
R/W R/W R/W R/W
R/Y R/L
Br B L/R G G B G
Gy Gy B Gy W Gy
Y/G Y/B
(BLACK)
B/Y (DARK GRAY)
Gy W W B W
L
Y/G
L Y/G B/L
B/Br B
B/L
B/Br B Gy/G B/L
R/L Gy/W
7-63
R R/B Gy/W R/L
B B
Gy/G B/L
W L
(BLACK)
Br/L L
B G
Br/L Br Br
G
Br Y/B Br
W/Y B/W G B
R R/Y R/Y G/L Br P
Br/W Br (BLACK) P
R/Y B Sb/W
R/G
Y/L Y L Dg Dg L Y
G
R/W
(BLACK)
(BLACK)
B R/L G Y Y G
B B Y Br B B G/B
G/L G/L G/Y G/Y
(BLACK)
B Y B/Y L/Y B B (BLACK)
Br B Y Br L/B G/L G/L L/B B N (BLACK)
G/B G/Y G/Y G/B (R)
(BLACK) (BLACK)
(GRAY) (GRAY)
W/B L/W L/W W/B
B P P B
Y/R Y/R
L
W/B L/B Dg Ch Ch Dg
L/B Br/W Br/W
Y Ch
(GRAY)
(GRAY)
A
L/B B
Y
L A L
B B L/B
L Y
L B
Ch A Ch
Y G
Dg A Dg
Ch Dg Ch L Dg L
B Y
(BLACK) Y B
(BLACK)
B G
Ch L L Ch Dg L L Dg
B B B B
B B
B B B
B
B A B B B
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
3. Main switch
4. Main fuse
6. Battery
11.Relay unit
13.Fuel pump relay
17.Fuel pump
77.Ignition fuse
7-64
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
NOTE:
1. Rider seat
2. Tool kit tray
4. Left side cover

(Main, fuel injection system, ignition
and ECU) Replace the fuse(s).
ES” on page 7-75.
OK ↓
page 7-76.
OK ↓
OK ↓
4. Check the engine stop switch. NG →
OK ↓
5. Check the relay unit (fuel pump re- NG →
lay).
Replace the relay unit.
Refer to “CHECKING THE RE-
OK ↓
OK ↓
7. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PUMP” on page 7-90.
OK ↓
7-65
FUEL PUMP SYSTEM
8. Check the entire fuel pump system NG →

wiring. Properly connect or repair the fuel pump
page 7-63.
OK ↓
Replace the ECU.
7-66
ELECTRICAL COMPONENTS
EAS27970
4 6
1
5
2
7 8
10
16
11
15 12
14
13
7-67
1. Cylinder-#2 right ignition coil (for XV19S(C)/

2. Cylinder-#2 left ignition coil (for XV19S(C)/
3. Fuel sender
4. Engine temperature sensor
5. Cylinder-#1 left ignition coil (for XV19S(C)/
Cylinder-#2 right ignition coil (for XV19CS(C)/
XV19C(C))
6. Cylinder-#1 right ignition coil (for XV19S(C)/
Cylinder-#1 right ignition coil (for XV19CS(C)/
XV19C(C))
7. Cylinder-#2 left ignition coil (for XV19CS(C)/
XV19C(C))
8. Cylinder-#1 left ignition coil (for XV19CS(C)/
XV19C(C))
10. EXUP servo motor
11. Speed sensor
13. Neutral switch
14. Horn 2
15. Horn 1
7-68
2 4
3
5
18
10
11
8
17 12
13
7
14
16
15
7-69

2. Main switch
6. Fuse box
7. Starter relay
9. Battery
12. Headlight relay
13. Relay unit
15. Main fuse
16. Lean angle cut-off switch
7-70
EAS27980
CHECKING THE SWITCHES
1
R Br L/Y L/B
R
ON
Br OFF
L/B L/Y
(GRAY)
13 Y G
Ch Br/W Dg B Y/R G/L
(BLUE) B B 2
R/W B/R
(L)
B B
R/W B/R
G/Y G/B
(R) G/L L/B
(GRAY)
3
P B L/W W/B
12 Y/R
L/W W/B
G/Y G/B (GRAY)

(BLACK)
PUSH
Ch Dg
Br/W
4
(GRAY) L/B G/L
11
Y G/L G
10 5
Br Y
B P
9 L/Y B/Y
B
B
(BLACK)
6
B
8 7 B
B B B B
(BLACK) (BLUE)
7-71
1. Main switch
3. Start switch
4. Accessory light switch
5. Front brake light switch
6. Neutral switch
7. Sidestand switch
9. Clutch switch
10. Horn switch
11. Dimmer switch
12. Select switch
13. Turn signal switch
7-72
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
CAUTION:
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
NOTE:
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown, blue/yellow and blue/black when the switch is
set to “ON”.
b
R Br L/Y L/B
ON
a
OFF
R L/B L/Y
Br
7-73
EAS27990
1. Remove:
CHECKING THE BULBS AND BULB
• Bulb
SOCKETS EW1D71009
NOTE: WARNING
Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot,
Check each bulb and bulb socket for damage or
away from them until they have cooled
wear, proper connections, and also for continuity
down.
between the terminals.
Damage/wear → Repair or replace the bulb, EC1D71006
CAUTION:
bulb socket or both.
Improperly connected → Properly connect. • Be sure to hold the socket firmly when re-
No continuity → Repair or replace the bulb, bulb moving the bulb. Never pull the lead, other-
socket or both. wise it may be pulled out of the terminal in
the coupler.
Types of bulbs • Avoid touching the glass part of a headlight
The bulbs used on this vehicle are shown in the bulb to keep it free from oil, otherwise the
illustration. transparency of the glass, the life of the
• Bulbs “a” and “b” are used for the headlights bulb, and the luminous flux will be adverse-
and usually use a bulb holder that must be de- ly affected. If the headlight bulb gets soiled,
tached before removing the bulb. The majority thoroughly clean it with a cloth moistened
of these types of bulbs can be removed from with alcohol or lacquer thinner.
their respective socket by turning them coun- 2. Check:
terclockwise. • Bulb (for continuity)
• Bulbs “c” are used for turn signal and tail/brake (with the pocket tester)
lights and can be removed from the socket by No continuity → Replace.
pushing and turning the bulb counterclockwise.
• Bulbs “d” and “e” are used for meter and indi- Pocket tester
cator lights and can be removed from their re- 90890-03112
spective socket by carefully pulling them out. Analog pocket tester
YU-03112-C
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
7-74
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
YU-03112-C
b. If the pocket tester indicates “∞”, replace the

fuse.
Checking the condition of the bulb sockets ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
The following procedure applies to all of the bulb 3. Replace:
sockets. • Blown fuse
1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Bulb socket (for continuity) a. Turn the main switch to “OFF”.
(with the pocket tester) b. Install a new fuse of the correct amperage
No continuity → Replace. rating.
c. Set on the switches to verify if the electrical
Pocket tester circuit is operational.
90890-03112 d. If the fuse immediately blows again, check
Analog pocket tester the electrical circuit.
YU-03112-C
XV19CTM(C)
NOTE:
Check each bulb socket for continuity in the Amperage
Fuses Q’ty
same manner as described in the bulb section; rating
however, note the following.
Main 50 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Ignition 25 A 1
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the re- Headlight 20 A 1
spective leads of the bulb socket. Fuel injection system 15 A 1
c. Check the bulb socket for continuity. If any of
Signaling system 10 A 1
the readings indicate no continuity, replace
the bulb socket. Taillight 10 A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ECU 10 A 1
EAS28000 Backup (odometer and
CHECKING THE FUSES 10 A 1
clock)
The following procedure applies to all of the fus-
Auxiliary DC connector 3A 1
es.
EC1D71019 Spare 25 A 1
CAUTION:
Spare 20 A 1
To avoid a short circuit, always turn the main
switch to “OFF” when checking or replacing Spare 15 A 1
a fuse. Spare 10 A 1
1. Remove: Spare 3A 1
• Rider seat
2. Check:
• Fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
7-75
For XV19CS(C)/ XV19C(C) • DO NOT SMOKE when charging or han-

dling batteries.
Amperage • KEEP BATTERIES AND ELECTROLYTE
Fuses Q’ty
rating OUT OF REACH OF CHILDREN.
Main 50 A 1 • Avoid bodily contact with electrolyte as it
Ignition 25 A 1 can cause severe burns or permanent eye
injury.
Headlight 20 A 1 FIRST AID IN CASE OF BODILY CONTACT:
Fuel injection system 15 A 1 EXTERNAL
Signaling system 10 A 1 • Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
Taillight 7.5 A 1 get immediate medical attention.
Backup (odometer and INTERNAL
7.5 A 1
clock) • Drink large quantities of water or milk fol-
Auxiliary DC connector 3A 1 lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical atten-
Spare 25 A 1
tion.
Spare 20 A 1 EC1D71020
Spare 15 A 1 CAUTION:
Spare 10 A 1 • This is a sealed battery. Never remove the
Spare 7.5 A 1 sealing caps because the balance between
cells will not be maintained and battery per-
Spare 3A 1 formance will deteriorate.
EWA13310 • Charging time, charging amperage and
WARNING charging voltage for an MF battery are dif-
Never use a fuse with an amperage rating ferent from those of conventional batteries.
other than that specified. Improvising or us- The MF battery should be charged accord-
ing a fuse with the wrong amperage rating ing to the instructions for the charging
may cause extensive damage to the electri- method. If the battery is overcharged, the
cal system, cause the lighting and ignition electrolyte level will drop considerably.
systems to malfunction and could possibly Therefore, take special care when charging
cause a fire. the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE:
4. Install: Since MF batteries are sealed, it is not possible
• Rider seat to check the charge state of the battery by mea-
Refer to “GENERAL CHASSIS” on page 4-1. suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
EAS28030
checked by measuring the voltage at the battery
CHECKING AND CHARGING THE BATTERY
EWA13290
terminals.
WARNING 1. Remove:
Batteries generate explosive hydrogen gas • Rider seat
and contain electrolyte which is made of poi- Refer to “GENERAL CHASSIS” on page 4-1.
sonous and highly caustic sulfuric acid. 2. Remove:
Therefore, always follow these preventive • ECU band “1”
measures:
• Wear protective eye gear when handling or
working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
7-76
NOTE:
• The charge state of an MF battery can be
1 checked by measuring its open-circuit voltage
(i.e., the voltage when the positive battery ter-
minal is disconnected).
• No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
b. Check the charge of the battery, as shown in
the charts and the following example.
3. Remove: Example
• Coupler tray “1” Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
1
4. Disconnect:
• Battery leads
(from the battery terminals)
ECA13640
CAUTION: A. Open-circuit voltage (V)

B. Charging time (hours)
First, disconnect the negative battery lead
C. Relationship between the open-circuit voltage
“1”, and then positive battery lead “2”. and the charging time at 20 °C (68 °F)
D. These values vary with the temperature, the
1 condition of the battery plates, and the
electrolyte level.
5. Remove:
• Battery
6. Check:
• Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ A. Open-circuit voltage (V)
a. Connect a pocket tester to the battery termi- B. Charging condition of the battery (%)
nals. C. Ambient temperature 20 °C (68 °F)
• Positive tester probe →
positive battery terminal ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe → 7. Charge:
negative battery terminal • Battery
(refer to the appropriate charging method il-
lustration)
7-77
EWA13300
WARNING
Do not quick charge a battery.
ECA13670
CAUTION:
• Never remove the MF battery sealing caps.
• Do not use a high-rate battery charger
since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful A. Open-circuit voltage (V)
not to overcharge the battery. B. Time (minutes)
• When charging a battery, be sure to remove C. Charging
it from the vehicle. (If charging has to be D. Ambient temperature 20 °C (68 °F)
done with the battery mounted on the vehi- E. Check the open-circuit voltage.
cle, disconnect the negative battery lead
from the battery terminal.) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• To reduce the chance of sparks, do not Charging method using a variable-current
plug in the battery charger until the battery (voltage) charger
charger leads are connected to the battery. a. Measure the open-circuit voltage prior to
• Before removing the battery charger lead charging.
clips from the battery terminals, be sure to NOTE:
turn off the battery charger. Voltage should be measured 30 minutes after
• Make sure the battery charger lead clips are the engine is stopped.
in full contact with the battery terminal and b. Connect a charger and ammeter to the bat-
that they are not shorted. A corroded battery and start charging.
tery charger lead clip may generate heat in
NOTE:
the contact area and a weak clip spring may
cause sparks. Set the charging voltage at 16–17 V. If the set-
• If the battery becomes hot to the touch at ting is lower, charging will be insufficient. If too
any time during the charging process, dis- high, the battery will be over-charged.
connect the battery charger and let the bat- c. Make sure that the current is higher than the
tery cool before reconnecting it. Hot standard charging current written on the bat-
batteries can explode! tery.
• As shown in the following illustration, the NOTE:
open-circuit voltage of an MF battery stabi-
If the current is lower than the standard charging
lizes about 30 minutes after charging has
current written on the battery, set the charging
been completed. Therefore, wait 30 min-
voltage adjust dial at 20–24 V and monitor the
utes after charging is completed before
amperage for 3–5 minutes to check the battery.
measuring the open-circuit voltage.
• Standard charging current is reached
Battery is good.
• Standard charging current is not reached
Replace the battery.
d. Adjust the voltage so that the current is at the
standard charging level.
e. Set the time according to the charging time
suitable for the open-circuit voltage.
7-78
f. If charging requires more than 5 hours, it is ECA13630
advisable to check the charging current after CAUTION:

a lapse of 5 hours. If there is any change in First, connect the positive battery lead “1”,
the amperage, readjust the voltage to obtain and then the negative battery lead “2”.
the standard charging current.
NOTE:
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30 Be sure to route the negative battery lead to-
minutes. wards the front of the vehicle and to install the
negative terminal cover “3” securely.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt-
age charger
a. Measure the open-circuit voltage prior to
charging. 1
NOTE:
Voltage should be measured 30 minutes after 10.Check:
the engine is stopped. • Battery terminals
Dirt → Clean with a wire brush.
b. Connect a charger and ammeter to the bat- Loose connection → Connect properly.
tery and start charging. 11.Lubricate:
c. Make sure that the current is higher than the • Battery terminals
standard charging current written on the bat-
tery. Recommended lubricant
NOTE: Dielectric grease
If the current is lower than the standard charging 12.Install:
current written on the battery, this type of battery • Coupler tray
charger cannot charge the MF battery. A vari- • ECU band
able voltage charger is recommended.
NOTE:
d. Charge the battery until the battery’s charg- Make sure the leads are routed correctly.
ing voltage is 15 V.
13.Install:
NOTE:
• Rider seat
Set the charging time at 20 hours (maximum). Refer to “GENERAL CHASSIS” on page 4-1.
e. Measure the battery open-circuit voltage after EAS28040
leaving the battery unused for more than 30 CHECKING THE RELAYS
minutes. Check each switch for continuity with the pocket
12.8 V or more --- Charging is complete. tester. If the continuity reading is incorrect, re-
12.7 V or less --- Recharging is required. place the relay.
Under 12.0 V --- Replace the battery.
Pocket tester
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 90890-03112
8. Install: Analog pocket tester
• Battery YU-03112-C
9. Connect:
1. Disconnect the relay from the wire harness.
• Battery leads
2. Connect the pocket tester (Ω × 1) and battery
(to the battery terminals)
(12 V) to the relay terminals as shown.
Check the relay operation.
7-79
Starter relay 2. Negative battery terminal

3. Positive tester probe
3
4. Negative tester probe
R
Result
R Continuity
R/Y L (between “3” and “4”)
B
2 1 Headlight relay
4 3
1. Positive battery terminal 4 +
2. Negative battery terminal
2 1
Y/B Br
Result G/L
Continuity R/Y
(between “3” and “4”)

1. Positive battery terminal
Relay unit (starting circuit cut-off relay) 2. Negative battery terminal
3 1 2 4 +
Result
Continuity
(between “3” and “4”)
ET1D71011
CHECKING THE TURN SIGNAL RELAY

1. Check:
• Turn signal relay input voltage
2. Negative battery terminal
Out of specification → The wiring circuit from
the main switch to the turn signal relay cou-
pler is faulty and must be repaired.
Turn signal relay input voltage

Result DC 12 V
Continuity
(between “3” and “4”) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal relay terminal as shown.
Relay unit (fuel pump relay)
Pocket tester
90890-03112
3 2 1 4 + Analog pocket tester
YU-03112-C

brown “1”
• Negative tester probe →
ground
7-80
EAS28050
CHECKING THE DIODES
Relay unit (diode)

1. Check:
• Relay unit (diode)
Pocket tester
90890-03112
YU-03112-C
b. Turn the main switch to “ON”.
c. Measure the turn signal relay input voltage.
NOTE:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
The pocket tester or the analog pocket tester
2. Check:
readings are shown in the following table.
• Turn signal relay output voltage
Turn signal relay output voltage

DC 12 V
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the
turn signal relay terminal as shown.
Pocket tester
90890-03112
YU-03112-C

brown/white “1”, yellow/red “2” or white/yel-
low “3”
ground

c. Measure the turn signal relay output voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-81
c. Check the relay unit (diode) for continuity.

Continuity d. Check the relay unit (diode) for no continuity.
Positive tester probe → sky blue
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
“1”
Negative tester probe → Diode 1 (for XV19S(C)/ XV19M(C)/
black/yellow “2” XV19CTS(C)/ XV19CTM(C))
No continuity 1. Check:
Positive tester probe → • Diode 1
black/yellow “2”
Negative tester probe → sky
blue “1” Pocket tester
Continuity 90890-03112
Positive tester probe → sky blue Analog pocket tester
“1” YU-03112-C
Negative tester probe →
blue/yellow “3”
No continuity NOTE:
Positive tester probe → The pocket tester and the analog pocket tester
blue/yellow “3” readings are shown in the following table.
Negative tester probe → sky
blue “1” Continuity
Continuity Positive tester probe → red/yel-
Positive tester probe → sky blue low “1”
“1” Negative tester probe →
Negative tester probe → sky red/white “2” or red/white “3”
blue/white “4” No continuity
No continuity Positive tester probe →
Positive tester probe → sky red/white “2” or red/white “3”
blue/white “4” Negative tester probe → red/yel-
Negative tester probe → sky low “1”
blue “1”
Continuity
Positive tester probe →
blue/green “5” 2 3
blue/yellow “3”
No continuity R/W R/W
blue/yellow “3” R/Y
blue/green “5” 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the diode 1 from the wire har-
5 3 1 2 4 ness.
b. Connect the pocket tester (Ω × 1) to the diode
1 terminals as shown.
c. Check the diode 1 for continuity.
d. Check the diode 1 for no continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Diode 2 (for XV19S(C)/ XV19M(C)/

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the relay unit from the wire har- 1. Check:
ness. • Diode 2
b. Connect the pocket tester (Ω × 1) to the relay Out of specification → Replace.
unit terminals as shown.
7-82
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Pocket tester a. Disconnect the spark plug cap from the spark
90890-03112 plug.
Analog pocket tester b. Connect the ignition checker “1” as shown.
YU-03112-C
Ignition checker
NOTE: 90890-06754
The pocket tester and the analog pocket tester Opama pet-4000 spark checker
readings are shown in the following table. YM-34487
Continuity
red/white “1”
black/red “2”
No continuity
black/red “2”
red/white “1”
2. Spark plug cap
c. Turn the main switch to “ON” and engine stop
1 switch to “ ”.
d. Measure the ignition spark gap “a”.
R/W e. Crank the engine by pushing the start switch
“ ” and gradually increase the spark gap un-
B/R til a misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2
EAS28070
CHECKING THE SPARK PLUG CAPS

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ The following procedure applies to all of the
a. Disconnect the diode 2 from the wire har- spark plug caps.
ness. 1. Check:
b. Connect the pocket tester (Ω × 1) to the diode • Spark plug cap resistance
2 terminals as shown. Out of specification → Replace.
c. Check the diode 2 for continuity.
d. Check the diode 2 for no continuity. Resistance
10.0 kΩ
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71012
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE IGNITION SPARK GAP a. Remove the spark plug cap from the spark
1. Check: plug lead.
• Ignition spark gap b. Connect the pocket tester (Ω × 1k) to the
Out of specification → Perform the ignition spark plug cap as shown.
system troubleshooting, starting with step 5.
Refer to “TROUBLESHOOTING” on page Pocket tester
7-4. 90890-03112
Minimum ignition spark gap YU-03112-C
6.0 mm (0.24 in)
NOTE:
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
7-83
Secondary coil resistance

8.64–12.96 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
Pocket tester
c. Measure the spark plug cap resistance. 90890-03112
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Analog pocket tester
EAS28100
YU-03112-C
CHECKING THE IGNITION COILS
The following procedure applies to all of the igni- • Negative tester probe →
tion coils. black/red “1”
1. Check: • Positive tester probe →
• Primary coil resistance spark plug lead “2”
Primary coil resistance

2.16–2.64 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the igni-
tion coil as shown.
Pocket tester c. Measure the secondary coil resistance.

90890-03112
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YU-03112-C EAS28120
CHECKING THE CRANKSHAFT POSITION

SENSOR
1. Disconnect:
black/red “1”
• Negative tester probe → • Crankshaft position sensor coupler
orange or gray/red “2” (from the wire harness)
2. Check:
• Crankshaft position sensor resistance
Out of specification → Replace the crank-
shaft position sensor.
Crankshaft position sensor resis-

tance
248–372 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
c. Measure the primary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Pocket tester
2. Check: 90890-03112
• Secondary coil resistance Analog pocket tester
YU-03112-C
7-84

gray “1”
black “2”
c. Turn the lean angle sensor to 65°.

d. Measure the lean angle sensor output volt-
B Gy
age.
2 1 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71013
b. Measure the crankshaft position sensor re- CHECKING THE STARTER MOTOR
sistance. OPERATION
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1. Check:
EAS28130 • Starter motor operation
CHECKING THE LEAN ANGLE SENSOR Does not operate → Perform the electric
1. Remove: starting system troubleshooting, starting with
• Lean angle sensor step 5.
2. Check: Refer to “TROUBLESHOOTING” on page
• Lean angle sensor output voltage 7-11.
Out of specification → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1” and
Lean angle sensor output voltage starter motor lead “2” with a jumper lead “3”.
Less than 65°: 0.4–1.4 V EWA13810
More than 65°: 3.7–4.4 V WARNING

• A wire that is used as a jumper lead must
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the lean angle sensor coupler to the have at least the same capacity of the bat-
wire harness. tery lead, otherwise the jumper lead may
b. Connect the pocket tester (DC 20 V) to the burn.
lean angle sensor coupler as shown. • This check is likely to produce sparks,
therefore, make sure no flammable gas or
Pocket tester fluid is in the vicinity.
90890-03112
YU-03112-C

yellow/green “1”
black/blue “2”
b. Check the starter motor operation.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28150
CHECKING THE STATOR COIL

1. Disconnect:
• Stator coil coupler
(from the rectifier/regulator)
7-85
2. Check: b. Connect the pocket tester (DC 20 V) to the

• Stator coil resistance rectifier/regulator coupler as shown.
Out of specification → Replace the stator coil.
Pocket tester
Stator coil resistance 90890-03112
0.112–0.168 Ω Analog pocket tester
YU-03112-C
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the stator • Positive tester probe →
coil coupler as shown. red “1”
Pocket tester black “2”
90890-03112
YU-03112-C

white “1”
white “2” W W W R B
• Positive tester probe → 1 2

white “1”
white “3” c. Start the engine and let it run at approximate-
ly 5000 r/min.
• Positive tester probe → d. Measure the charging voltage.
white “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe → EAS28180
white “3” CHECKING THE HORNS
1. Check:
• Horn resistance
Coil resistance
0.94–0.98 Ω
W W W ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn 1 connectors and horn 2
coupler from the horn terminals.
1 2 3 b. Connect the pocket tester (Ω × 1) to the horn
b. Measure the stator coil resistance. terminals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Pocket tester
EAS28170 90890-03112
CHECKING THE RECTIFIER/REGULATOR Analog pocket tester
1. Check: YU-03112-C
• Charging voltage
Out of specification → Replace the rectifi- • Positive tester probe →
er/regulator. horn terminal “1”
Charging voltage horn terminal “2”
14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the cylinder-#1
left spark plug lead or right spark plug lead.
7-86
A A
1 2
a b
B 1 2 B
a b
A. Horn 1 A. Horn 1
B. Horn 2 B. Horn 2
c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28210
2. Check: CHECKING THE ENGINE TEMPERATURE

• Horn sound SENSOR
Faulty sound → Adjust or replace. 1. Remove:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Engine temperature sensor
a. Connect a battery (12 V) to the horn. (from the front cylinder head)
b. Turn the adjusting screw in direction “a” or “b” EWA14140
until the horn sound is obtained. WARNING

• Handle the engine temperature sensor with
special care.
• Never subject the engine temperature sen-
sor to strong shocks. If the engine temper-
ature sensor is dropped, replace it.
2. Check:
• Engine temperature sensor resistance
Engine temperature sensor resis-

tance
0.90–1.10 kΩ at 100 °C (212 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1 k) to the en-
gine temperature sensor terminals as shown.
Pocket tester
90890-03112
YU-03112-C
7-87

green “1”
3 • Negative tester probe →
1 black “2”
b. Move the fuel sender float to maximum

“3”/minimum “4” level position.
2
3
1 2
b. Immerse the engine temperature sensor “1”
in a container filled with water “2”. G B
NOTE:
Make sure that the engine temperature sensor
terminals do not get wet.
4
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down to c. Measure the fuel sender resistance.
the specified temperature. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
e. Measure the engine temperature sensor re- ET1D71015
sistance. CHECKING THE FUEL SENDER (FUEL

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ PUMP)
3. Install: 1. Drain the fuel.
• Engine temperature sensor 2. Disconnect:
• Fuel pump coupler
Engine temperature sensor (from the fuel pump)
20 Nm (2.0 m·kg, 14 ft·lb) 3. Remove:
T.
R.
• Fuel pump
ET1D71014 (from the sub-fuel tank)
CHECKING THE FUEL SENDER (FUEL 4. Check:
TANK) • Fuel sender resistance
1. Remove: Out of specification → Replace the fuel pump
• Fuel sender assembly.
(from the fuel tank)
2. Check: Fuel sender resistance
• Fuel sender resistance 0.90–2.05 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Fuel sender (fuel tank) a. Connect the pocket tester (Ω × 1) to the fuel
Sender unit resistance (full) sender terminals as shown.
9–11 Ω
Sender unit resistance (empty) Pocket tester
213–219 Ω 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C
a. Connect the pocket tester (Ω × 100) to the
fuel sender coupler as shown. • Positive tester probe →
green/white “1”
Pocket tester • Negative tester probe →
90890-03112 black “2”
YU-03112-C
7-88
Pocket tester
90890-03112
2 1 Analog pocket tester
G/W B
YU-03112-C
R/L B
white “1”
black “2”
b. Measure the fuel sender resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 1
ET1D71044
CHECKING THE FUEL LEVEL WARNING

LIGHT W L L W/Y
This model is equipped with a self-diagnosis de- B B/ L
vice for the fuel level detection circuit.
1. Check:
2
• Fuel level warning light “1”
(Turn the main switch to “ON”.)
Warning light comes on for a few seconds,
c. Elevate the rear wheel and slowly rotate it.
then goes off → Warning light is OK.
d. Measure the voltage of white and black. With
Warning light does not come on → Replace
each full rotation of the rear wheel, the volt-
the meter assembly.
age reading should cycle from 0.6 V to 4.8 V
Warning light flashes eight times, then goes
to 0.6 V to 4.8 V.
off for three seconds in a repeated cycle (mal-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
function detected in fuel sender or thermistor)
→ Replace the fuel pump assembly. EAS28300
CHECKING THE THROTTLE POSITION

SENSOR
1. Remove:
• Throttle position sensor
(from the throttle body)
2. Check:
1 • Throttle position sensor maximum resistance
Out of specification → Replace the throttle
position sensor.
Resistance
EAS28240 XV19S(C)/ XV19M(C)/
CHECKING THE SPEED SENSOR XV19CTS(C)/ XV19CTM(C):
1. Check: 4.0–6.0 kΩ/blue-black
• Speed sensor output voltage XV19CS(C)/ XV19C(C):
Out of specification → Replace. 3.1–5.7 kΩ/blue-black
Output voltage reading cycle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

0.6 V to 4.8 V to 0.6 V to 4.8 V a. Connect the pocket tester (Ω × 1k) to the
throttle position sensor terminals as shown.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the Pocket tester
speed sensor coupler as shown. 90890-03112
YU-03112-C
7-89
• Positive tester probe → c. Connect the battery (DC 12 V) to the fuel

blue “1” pump terminals as shown.
• Negative tester probe → • Positive battery lead →
black “2” red/blue “2”
• Negative battery lead →
black “3”
2 1
3 2
B
G/W B
R/L
B Y L
1
b. Measure the throttle position sensor maxi-

mum resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ d. Check the fuel pump operation.
3. Install: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Throttle position sensor EAS28360
NOTE: CHECKING THE EXUP SERVO MOTOR

1. Check:
When installing the throttle position sensor, ad-
• EXUP servo motor operation
just its angle properly. Refer to “ADJUSTING
THE THROTTLE POSITION SENSOR” on page
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
6-16. a. Disconnect the EXUP cables from the EXUP
servo motor pulley.
EAS28350
b. Disconnect the EXUP servo motor coupler
CHECKING THE FUEL PUMP
EWA13850 from the wire harness.
WARNING c. Connect the battery leads to the EXUP servo
Gasoline is extremely flammable and under motor terminals as shown.
certain circumstances there can be a danger For counterclockwise rotation “a”
of an explosion or fire. Be extremely careful • Positive battery lead →
and note the following points: black/green “1”
• Stop the engine before refueling. • Negative battery lead →
black/red “2”
• Do not smoke, and keep away from open
For clockwise rotation “b”
flames, sparks, or any other source of fire. • Positive battery lead →
• If you do accidentally spill gasoline, wipe it black/red “2”
up immediately with dry rags. • Negative battery lead →
• If gasoline touches the engine when it is black/green “1”
hot, a fire may occur. Therefore, make sure
the engine is completely cool before per-
forming the following test. 1 2
1. Disconnect:
• Fuel pump coupler b
(from the fuel pump)
2. Check:
• Fuel pump operation a L W/R B/L
B/G B/R
Faulty/rough movement → Replace.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the fuel tank.
b. Put the end of the fuel hose “1” into an open d. Check that the EXUP servo motor pulley ro-
container. tates several times in directions “a” and “b”.
7-90
ECA14390 EW1D71004
CAUTION: WARNING
To prevent damaging the EXUP servo motor, • Handle the air temperature sensor with
perform this test within a few seconds of special care.
connecting the battery. • Never subject the air temperature sensor to
strong shocks. If the air temperature sen-
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
sor is dropped, replace it.
EAS28410
CHECKING THE INTAKE AIR PRESSURE 2. Check:

SENSOR • Air temperature sensor resistance
The following procedure applies to both of the in- Out of specification → Replace.
take air pressure sensors.
1. Check: Air temperature sensor resis-
• Intake air pressure sensor output voltage tance
290–390 Ω at 80 °C (176 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Intake air pressure sensor output a. Connect the pocket tester (Ω × 100) to the air
voltage
temperature sensor terminals as shown.
3.75–4.25 V
Pocket tester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the in- 90890-03112
take air pressure sensor coupler as shown.
YU-03112-C
Pocket tester
90890-03112
YU-03112-C 3
1
pink/white “1” or pink/yellow
black/blue “2” 2
b. Immerse the air temperature sensor “1” in a

2 1 container filled with water “2”.
NOTE:
B/L P/W L Make sure that the air temperature sensor termi-
nals 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 temperature.
b. Turn the main switch to “ON”. e. Measure the air temperature sensor resis-
c. Measure the intake air pressure sensor out- tance.
put voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71016
CHECKING THE AIR TEMPERATURE

SENSOR
1. Remove:
• Air temperature sensor
7-91
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
GENERAL INFORMATION ....................................................................... 8-1
STARTING FAILURES..............................................................................8-1
INCORRECT ENGINE IDLING SPEED .................................................... 8-1
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ........................... 8-2
FAULTY GEAR SHIFTING........................................................................ 8-2
SHIFT PEDAL DOES NOT MOVE ............................................................ 8-2
JUMPS OUT OF GEAR.............................................................................8-2
FAULTY CLUTCH .....................................................................................8-2
OVERHEATING ........................................................................................8-3
POOR BRAKING PERFORMANCE.......................................................... 8-3
FAULTY FRONT FORK LEGS..................................................................8-3
UNSTABLE HANDLING ............................................................................8-3
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 8-4
8
TROUBLESHOOTING
EAS28450
• Sucked-in air
TROUBLESHOOTING
EAS28460
Electrical system
GENERAL INFORMATION 1. Battery
NOTE:
• Discharged battery
• Faulty battery
The following guide for troubleshooting does not
2. Fuse(s)
cover all the possible causes of trouble. It should
• Blown, damaged or incorrect fuse
be helpful, however, as a guide to basic trouble-
• Improperly installed fuse
shooting. Refer to the relative procedure in this
3. Spark plug(s)
manual for checks, adjustments, and replace-
• Incorrect spark plug gap
ment of parts.
• Incorrect spark plug heat range
• Fouled spark plug
EAS28470
STARTING FAILURES • Worn or damaged electrode

• Worn or damaged insulator
Engine • Faulty spark plug cap
1. Cylinder(s) and cylinder head(s) 4. Ignition coil(s)
• Loose spark plug • Cracked or broken ignition coil body
• Loose cylinder head or cylinder • Broken or shorted primary or secondary coils
• Damaged cylinder head gasket • Faulty spark plug lead
• Damaged cylinder gasket 5. Ignition system
• Worn or damaged cylinder • Faulty ECU
• Incorrect valve clearance • Faulty crankshaft position sensor
• Improperly sealed valve • Broken generator rotor woodruff key
• Incorrect valve-to-valve-seat contact 6. Switches and wiring
• Incorrect valve timing • Faulty main switch
• Faulty valve spring • Faulty engine stop switch
• Seized valve • Broken or shorted wiring
2. Piston(s) and piston ring(s) • Faulty neutral switch
• Improperly installed piston ring • Faulty start switch
• Damaged, worn or fatigued piston ring • Faulty sidestand switch
• Seized piston ring • Faulty clutch switch
• Seized or damaged piston • Improperly grounded circuit
3. Air filter • Loose connections
• Improperly installed air filter 7. Starting system
• Clogged air filter element • Faulty starter motor
4. Crankcase and crankshaft • Faulty starter relay
• Improperly assembled crankcase • Faulty relay unit (starting circuit cut-off relay)
• Seized crankshaft • Faulty starter clutch
EAS28490
Fuel system INCORRECT ENGINE IDLING SPEED
1. Fuel tank
• Empty fuel tank Engine
• Clogged fuel filter 1. Cylinder(s) and cylinder head(s)
• Clogged fuel tank overflow/breather hose • Incorrect valve clearance
• Clogged rollover valve • Damaged valve train components
• Clogged rollover valve hose 2. Air filter
• Deteriorated or contaminated fuel • Clogged air filter element
2. Fuel pump
• Faulty fuel pump Fuel system
• Faulty relay unit (fuel pump relay) 1. Throttle body(-ies)
3. Throttle body(-ies) • Damaged or loose throttle body joint
• Deteriorated or contaminated fuel • Improperly synchronized throttle bodies
8-1
TROUBLESHOOTING
• Improper throttle cable free play • Foreign object between transmission gears
• Flooded throttle body • Improperly assembled transmission
EAS28550
Electrical system JUMPS OUT OF GEAR
1. Battery
• Discharged battery Shift shaft
• Faulty battery • Incorrect shift pedal position
2. Spark plug(s) • Improperly returned stopper lever
• Incorrect spark plug gap
• Incorrect spark plug heat range Shift forks
• Fouled spark plug • Worn shift fork
• Worn or damaged electrode
• Worn or damaged insulator Shift drum
• Faulty spark plug cap • Incorrect axial play
3. Ignition coil(s) • Worn shift drum groove
• Broken or shorted primary or secondary coils
• Faulty spark plug lead Transmission
• Cracked or broken ignition coil • Worn gear dog
4. Ignition system
EAS28570
• Faulty ECU FAULTY CLUTCH
• Faulty crankshaft position sensor
• Broken generator rotor woodruff key Clutch slips
EAS28510 1. Clutch
POOR MEDIUM AND HIGH-SPEED • Improperly assembled clutch
PERFORMANCE • Improperly assembled clutch master cylinder
Refer to “STARTING FAILURES” on page 8-1. • Improperly assembled clutch release cylinder
• Incorrect clutch fluid level
Engine • Damaged clutch hose
1. Air filter • Loose or fatigued clutch spring
• Clogged air filter element • Loose union bolt
• Worn friction plate
Fuel system • Worn clutch plate
1. Fuel pump • Damaged clutch release cylinder
• Faulty fuel pump 2. Engine oil
EAS28530
• Incorrect oil level
FAULTY GEAR SHIFTING • Incorrect oil viscosity (low)
• Deteriorated oil
Shifting is difficult
Refer to “Clutch drags”. Clutch drags
1. Clutch
EAS28540
• Air in hydraulic clutch system
SHIFT PEDAL DOES NOT MOVE
• Unevenly tensioned clutch springs
Shift shaft • Warped pressure plate
• Improperly adjusted shift rod • Bent clutch plate
• Bent shift shaft • Swollen friction plate
• Bent clutch push rod
Shift drum and shift forks • Damaged clutch boss
• Foreign object in a shift drum groove • Burnt primary driven gear bushing
• Seized shift fork • Damaged clutch release cylinder
• Bent shift fork guide bar • Match marks not aligned
2. Engine oil
Transmission • Incorrect oil level
• Seized transmission gear • Incorrect oil viscosity (high)
8-2
TROUBLESHOOTING
• Deteriorated oil • Damaged damper rod assembly bolt copper

washer
EAS28590
OVERHEATING • Cracked or damaged cap bolt O-ring
Engine Malfunction
1. Cylinder head(s) and piston(s) • Bent or damaged inner tube
• Heavy carbon buildup • Bent or damaged outer tube
2. Engine oil • Damaged fork spring
• Incorrect oil level • Worn or damaged outer tube bushing
• Incorrect oil viscosity • Bent or damaged damper rod
• Inferior oil quality • Incorrect oil viscosity
• Incorrect oil level
Fuel system EAS28670
1. Throttle body(-ies) UNSTABLE HANDLING

• Faulty throttle body(-ies) 1. Handlebar
• Damaged or loose throttle body joint • Bent or improperly installed handlebar
2. Air filter 2. Steering head components
• Clogged air filter element • Improperly installed upper bracket
• Improperly installed lower bracket
Chassis (improperly tightened ring nut)
1. Brake(s) • Bent steering stem
• Dragging brake • Damaged ball bearing or bearing race
3. Front fork leg(s)
Electrical system • Uneven oil levels (both front fork legs)
1. Spark plug(s) • Unevenly tensioned fork spring (both front
• Incorrect spark plug gap fork legs)
• Incorrect spark plug heat range • Broken fork spring
2. Ignition system • Bent or damaged inner tube
• Faulty ECU • Bent or damaged outer tube
EAS28620
4. Swingarm
POOR BRAKING PERFORMANCE • Worn bearing or bushing
• Worn brake pad • Bent or damaged swingarm
• Worn brake disc 5. Rear shock absorber assembly
• Air in hydraulic brake system • Faulty rear shock absorber spring
• Leaking brake fluid • Leaking oil or gas
• Faulty brake caliper kit 6. Tire(s)
• Faulty brake caliper seal • Uneven tire pressures (front and rear)
• Loose union bolt • Incorrect tire pressure
• Damaged brake hose • Uneven tire wear
• Oil or grease on the brake disc 7. Wheel(s)
• Oil or grease on the brake pad • Incorrect wheel balance
• Incorrect brake fluid level • Deformed cast wheel
• Damaged wheel bearing
EAS28660
FAULTY FRONT FORK LEGS • Bent or loose wheel axle

• Excessive wheel runout
Leaking oil 8. Frame
• Bent, damaged or rusty inner tube • Bent frame
• Cracked or damaged outer tube • Damaged steering head pipe
• Improperly installed oil seal • Improperly installed bearing race
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
8-3
TROUBLESHOOTING
EAS28710
• Faulty turn signal relay
FAULTY LIGHTING OR SIGNALING SYSTEM
• Burnt-out turn signal bulb
Headlight does not come on
Horn does not sound
• Wrong headlight bulb
• Improperly adjusted horn
• Too many electrical accessories
• Damaged or faulty horn
• Hard charging
• Faulty main switch
• Incorrect connection
• Faulty horn switch
• Improperly grounded circuit
• Faulty battery
• Poor contacts (main switch)
• Burnt-out headlight bulb
• Faulty wire harness
Headlight bulb burnt out
• Wrong headlight bulb
• Faulty battery
• Faulty rectifier/regulator
• Headlight bulb life expired
Tail/brake light does not come on

• Wrong tail/brake light LED
• Too many electrical accessories
• Burnt-out tail/brake light LED
Tail/brake light LED burnt out

• Wrong tail/brake light LED
• Faulty battery
• Incorrectly adjusted rear brake light switch
• Tail/brake light LED life expired
Turn signal does not come on

• Faulty turn signal switch
• Damaged or faulty wire harness
• Faulty battery
Turn signal flashes slowly

• Faulty turn signal switch
• Incorrect turn signal bulb
Turn signal remains lit

Turn signal flashes quickly

• Incorrect turn signal bulb
8-4
EAS28740
54. Clutch switch EAS28750
WIRING DIAGRAM 55. Dimmer switch COLOR CODE

XV19SX(C)/XV19MX(C)/XV19CT 56. Turn signal switch B Black
SX(C)/XV19CTMX(C) 2008 57. Horn switch Br Brown
1. AC magneto 58. Select switch Ch Chocolate
59. Front right turn signal/position Dg Dark green
G Green
3. Main switch light
Gy Gray
4. Main fuse 60. Front left turn signal/position L Blue
5. Backup fuse (odometer and light O Orange
clock) 61. Headlight assembly P Pink
6. Battery 62. Headlight (high beam) R Red
7. Fuel injection system fuse 63. Headlight (low beam) Sb Sky blue
8. Starter relay 64. Right handlebar switch W White
9. Starter motor 65. Front brake light switch Y Yellow
10. Diode 1 66. Engine stop switch B/Br Black/Brown
67. Start switch B/G Black/Green
11. Relay unit
B/L Black/Blue
12. Starting circuit cut-off relay 68. Accessory light switch
B/R Black/Red
13. Fuel pump relay 69. Accessory light (OPTION) B/Y Black/Yellow
14. Neutral switch 70. Tail/brake light assembly Br/L Brown/Blue
15. Diode 2 71. Tail/brake light Br/W Brown/White
16. Sidestand switch 72. License plate light G/L Green/Blue
17. Fuel pump 73. Rear left turn signal light G/R Green/Red
18. Fuel sender (fuel pump) 74. Rear right turn signal light G/W Green/White
19. Crankshaft position sensor 75. Rear brake light switch G/Y Green/Yellow
20. Throttle position sensor 76. Auxiliary DC coupler Gy/G Gray/Green
21. Cylinder-#1 intake air pressure 77. Auxiliary DC connector fuse Gy/R Gray/Red
78. Ignition fuse Gy/W Gray/White
sensor
L/B Blue/Black
22. Cylinder-#2 intake air pressure 79. Headlight fuse
L/G Blue/Green
sensor 80. Signaling system fuse L/R Blue/Red
23. Lean angle sensor 81. Taillight fuse L/W Blue/White
24. Speed sensor 82. ECU fuse L/Y Blue/Yellow
25. Air temperature sensor P/L Pink/Blue
26. Engine temperature sensor P/W Pink/White
27. ECU (electronic control unit) P/Y Pink/Yellow
28. Cylinder-#1 left ignition coil R/B Red/Black
29. Cylinder-#1 right ignition coil R/G Red/Green
R/L Red/Blue
30. Cylinder-#2 left ignition coil
R/W Red/White
31. Cylinder-#2 right ignition coil R/Y Red/Yellow
32. Spark plug Sb/W Sky blue/White
33. ISC (idle speed control) unit W/B White/Black
34. EXUP servo motor W/G White/Green
35. Injector #2 W/R White/Red
36. Injector #1 W/Y White/Yellow
37. O2 sensor Y/B Yellow/Black
38. Meter assembly Y/G Yellow/Green
Y/L Yellow/Blue
39. Neutral indicator light
Y/R Yellow/Red
40. Multi-function meter
41. Reset switch
42. Engine trouble warning light
43. Fuel level warning light
44. Meter light
45. Left turn signal indicator light
46. Right turn signal indicator light
47. High beam indicator light
48. Fuel sender (fuel tank)
49. Horn 1
50. Horn 2
52. Headlight relay
53. Left handlebar switch
EAS1D77006
56. Front right turn signal/position EAS1D77011
WIRING DIAGRAM light COLOR CODE

XV19CSX(C)/XV19CX(C) 2008 57. Front left turn signal/position B Black
1. AC magneto light Br Brown
2. Rectifier/regulator 58. Headlight Ch Chocolate
59. Accessory light (OPTION) Dg Dark green
3. Main switch
G Green
4. Main fuse 60. Right handlebar switch
Gy Gray
5. Battery 61. Front brake light switch L Blue
6. Fuel injection system fuse 62. Engine stop switch O Orange
7. Starter relay 63. Start switch P Pink
8. Starter motor 64. Accessory light switch R Red
9. Relay unit 65. Rear right turn signal light Sb Sky blue
10. Starting circuit cut-off relay 66. Rear left turn signal light W White
11. Fuel pump relay 67. License plate light Y Yellow
12. Neutral switch 68. Tail/brake light B/Br Black/Brown
69. Rear brake light switch B/G Black/Green
13. Sidestand switch
B/L Black/Blue
14. Fuel pump 70. Auxiliary DC coupler
B/R Black/Red
15. Fuel sender (fuel pump) 71. Auxiliary DC connector fuse B/Y Black/Yellow
16. Engine temperature sensor 72. Ignition fuse Br/L Brown/Blue
17. Crankshaft position sensor 73. Signaling system fuse Br/W Brown/White
18. Throttle position sensor 74. Taillight fuse G/L Green/Blue
19. Cylinder-#1 intake air pressure 75. Headlight fuse G/R Green/Red
sensor 76. Backup fuse (odometer and G/W Green/White
20. Cylinder-#2 intake air pressure clock) G/Y Green/Yellow
sensor Gy/G Gray/Green
21. Speed sensor Gy/R Gray/Red
Gy/W Gray/White
22. Lean angle sensor
L/B Blue/Black
23. Air temperature sensor L/G Blue/Green
24. ECU (electronic control unit) L/R Blue/Red
25. Cylinder-#1 left ignition coil L/W Blue/White
26. Cylinder-#1 right ignition coil L/Y Blue/Yellow
27. Cylinder-#2 left ignition coil P/L Pink/Blue
28. Cylinder-#2 right ignition coil P/W Pink/White
29. Spark plug P/Y Pink/Yellow
30. Injector #2 R/B Red/Black
31. Injector #1 R/G Red/Green
R/L Red/Blue
32. O2 sensor
R/W Red/White
33. EXUP servo motor R/Y Red/Yellow
34. ISC (idle speed control) unit Sb/W Sky blue/White
35. Meter assembly W/B White/Black
36. Neutral indicator light W/G White/Green
37. Multi-function meter W/R White/Red
38. Engine trouble warning light W/Y White/Yellow
39. Fuel level warning light Y/B Yellow/Black
40. Reset switch Y/G Yellow/Green
Y/L Yellow/Blue
41. Meter light
Y/R Yellow/Red
42. High beam indicator light
43. Left turn signal indicator light
44. Right turn signal indicator light
45. Fuel sender (fuel tank)
46. Horn 1
47. Horn 2
49. Headlight relay
50. Left handlebar switch
51. Clutch switch
52. Dimmer switch
53. Turn signal switch
54. Horn switch
55. Select switch
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
XV19SX(C)/XV19MX(C)/XV19CTSX(C)/XV19CTMX(C) 2008 WIRING DIAGRAM
15
11
12 13
16
(BLUE)
17 18 28 32 B
(BLUE)
C 29 32
14 WIRE HARNESS SUB-WIRE-HARNESS2
C
C C
30 32
4
1 2 (BLACK) (BLACK)
D
19 D
33 31 32
(BLACK)
24 D
D
(GRAY)
5 D
E
20 E 27
3 (BLACK)
E
DD
ON 7
OFF (BLACK) (BLACK)
(GRAY) (GRAY) 6 8 21 WIRE HARNESS SUB-WIRE-HARNESS4

(BLACK)
34
22 (BLACK) E
10
9 (BLACK) 25
(BLACK) 35 (GRAY)
B B B
26 B
B
36 (DARK GRAY)
(BLACK) B
23
82
37
(BLACK)
81
80
38
79 51 (BLACK) 50 49 48 39
77 78 52
40
75 64 53 41
76
55 56 57 58 (BLACK)
(BLACK)
(BLACK)
66 67 68 (BLUE) (BLUE)
54 (L) PUSH
N
(BLACK)
(R) 42 (BLACK) (BLACK)
(BLACK)
65 (GRAY) (GRAY) 43
44
45
70 46
69 (GRAY)
(GRAY)
47
61
71
72 73 74 62 63
(BLACK)
(BLACK)
60 59

XV19CSX(C)/XV19CX(C) 2008 WIRING DIAGRAM
9
10 11
(BLACK) (BLACK)
(BLACK)
A
4 29
1 2 14 15 25
13 (BLUE) (BLUE) (GRAY)
26 29 WIRE HARNESS SUB-WIRE-HARNESS1

(GRAY)
12 B 27 29
C
16
17
3 29
ON 6 28
OFF 30 (GRAY)
C B B
5 18 C
(RED) (RED)
7 24 31 (DARK GRAY)
C
B B
(BLACK) 19
B
(BLACK) 20
B
8 23 (BLACK)
32 WIRE HARNESS SUB-WIRE-HARNESS2
(BLACK)
21
33
22 (BLACK)
34
(BLACK)
76
75
74
73
35
72 49 47 46
48 36
71 (BLACK)
69
(BLACK) (BLACK)
50 37
52 53 54 55
60 (GREEN) (GREEN)
(L) PUSH 38
70 62 63 64
N
(R)
(BLACK) (BLACK)
51 39 45
(YELLOW) (YELLOW)
(BLACK) 40
61 41
(BLACK) (BLACK) (GRAY)
(GRAY)
42
43
A A
A
A 44 (BLACK)
(BLACK)
68 67 66 65 58 57 56
59
(YELLOW) (GRAY) (BLACK)
(GRAY) (BLACK)
(YELLOW) (GRAY) (BLACK)

(GRAY) (BLACK)

00 Yamaha Raider Service Manual

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2008

IMPORTANT MANUAL INFORMATION

Failure to follow WARNING instructions could result in severe injury or death

A CAUTION indicates special precautions that must be taken to avoid dam-

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

18. Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

IMPORTANT INFORMATION ....................................................................... 1-11

CHECKING THE CONNECTIONS ................................................................1-13

SPECIAL TOOLS .......................................................................................... 1-14

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE FI SYSTEM

1. Pressure regulator 13. Intake air pressure sensor

INSTRUMENT FUNCTIONS (for XV19S(C)/

Multi-function meter unit

Tachometer • The fuel gauge does not indicate the correct

Odometer, tripmeter, and clock modes

To set the clock: Select the brightness control mode as follows.

Brightness control mode

• a fuel reserve tripmeter (which shows the dis-

INSTRUMENT FUNCTIONS (for XV19CS(C)/ 1. “SELECT” switch

Multi-function meter unit

Fuel gauge b. Estimation range

a. Fuel sender detection range

odometer display will automatically change to CAUTION:

To set the clock

1. Multi-function meter unit panel

To set the brightness

1. Multi-function meter unit panel

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS Pocket tester

Tappet adjusting tool (4 mm) 3-6, 3-7

Oil filter wrench 3-12

Belt tension gauge 3-26

Steering nut wrench 3-27, 4-81

Damper rod holder 4-71, 4-73

T-handle 4-71, 4-73

Fork seal driver 4-73, 4-74

Pivot shaft wrench 5-15

Valve spring compressor 5-42, 5-47

Valve guide installer (ø6) 5-43

Valve guide reamer (ø6) 5-43

Piston pin puller set 5-49

Universal clutch holder 5-64, 5-69

Sheave holder 5-64, 5-68,

Rotor puller 5-79

Vacuum/pressure pump gauge set 6-16

Pressure gauge 6-16

Fuel pressure adapter 6-16

Digital circuit tester 6-16

Ignition checker 7-83

GENERAL SPECIFICATIONS ........................................................................ 2-1

ENGINE SPECIFICATIONS ............................................................................2-3

CHASSIS SPECIFICATIONS ........................................................................2-11

ELECTRICAL SPECIFICATIONS .................................................................2-16

TIGHTENING TORQUES .............................................................................. 2-20