Yamaha XV19SX(C), XV19MX(C), XV19CTSX(C), XV19CTMX(C), XV19CSX(C) 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

First edition, June 2007

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 manual. 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 vehicle 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 vehicle 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 significant 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 system. 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 vehicle.

CAUTION:

NOTE:

A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle.

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 disassembly 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 sequentially.

EAS20100

SYMBOLS

The following symbols are used in this manual for easier understanding.

NOTE:

The following symbols are not relevant to every vehicle.

123

456

1. Serviceable with engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening torque

6. Wear limit, clearance

7. Engine speed

8. Electrical data

9. Engine oil

10.Gear oil

11.Molybdenum-disulfide oil

12.Brake fluid

13.Wheel-bearing grease

14.Lithium-soap-based grease

15.Molybdenum-disulfide grease

16.Silicone grease

17.Apply locking agent (LOCTITE®).

18.Replace the part with a new one.

910

11 12

13 14

15 16

17 18

New

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

GENERAL INFORMATION

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

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1

MODEL LABEL..........................................................................................1-1

FEATURES...................................................................................................... 1-2

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

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.

IDENTIFICATION

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 conditions, 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 airfuel ratio can be achieved to accommodate the constant changes in the operating conditions of the engine. 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 accommodate 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.

345678910 11121314

2223

1. Air temperature sensor

2. ISC (idle speed control) unit

3. Cylinder-#2 intake air pressure sensor

4. Engine temperature sensor

5. Cylinder-#2 left and right ignition coils (for XV19CS(C)/ XV19C(C))

6. Cylinder-#1 right ignition coil (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))

7. Throttle position sensor

8. Cylinder-#1 left and right ignition coils (for XV19CS(C)/ XV19C(C))

9. Cylinder-#1 left ignition coil (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))

10.Cylinder-#1 intake air pressure sensor

11.Fuel pump

16 1518 21 20 19 18 17

12.ECU (electronic control unit)

13.Relay unit (fuel pump relay)

14.EXUP servo motor

15.Speed sensor

16.O

sensor

17.Lean angle sensor

18.Spark plug

19.Injector #1

20.Crankshaft position sensor

21.Injector #2

22.Cylinder-#2 right ignition coil (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))

23.Cylinder-#2 left ignition coil (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))

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. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume 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 O

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.

sensor enable the ECU to determine the injection

1. Pressure regulator

2. Fuel pump

3. Fuel injector

4. Ignition coil

5. ECU (electronic control unit)

6. Air temperature sensor

7. ISC (idle speed control) unit

8. Throttle position sensor

9. O

sensor

10.Catalytic converter

11.Engine temperature sensor

12.Crankshaft position sensor

13.Intake air pressure sensor

14.Throttle body

15.Air filter case

A. Fuel system B. Air system C. Control system

1-3

ET1D71036

INSTRUMENT FUNCTIONS (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))

Multi-function meter unit

EW1D71008

WARNING

Be sure to stop the vehicle before making any setting changes to the multi-function meter unit.

FEATURES

1. Speedometer

2. Fuel gauge

3. Odometer/tripmeter/fuel reserve tripmeter/clock

4. Tachometer

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 traveled since they were last set to zero)

• a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve)

• a clock

• a self-diagnosis device

• a brightness control mode

NOTE:

• Be sure to turn the key to “ON” before using the “SELECT” and “RESET” switches, except for

setting the brightness control mode.

• To switch the odometer, the tripmeters and the fuel reserve tripmeter displays between kilometers and miles, press the “SELECT” switch for at least two seconds. (for USA and California only)

1. “SELECT” switch

2. “RESET” switch

Speedometer

1. Speedometer

The speedometer shows the riding speed. When the key is turned to “ON”, the speedometer needle will sweep once across the speed range and then return to zero in order to test the electrical circuit.

1-4

FEATURES

Tachometer

1. Tachometer

2. Tachometer red zone

The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. When the key is turned to “ON”, the tachometer needle will sweep once across the r/min range and then return to zero r/min in order to test the electrical circuit.

EC1D71017

CAUTION:

Do not operate the engine in the tachometer red zone. Red zone: 5000 r/min and above

Fuel gauge

1. Fuel gauge

The fuel gauge indicates the amount of fuel in the fuel tank. The needle moves towards “E” (Empty) as the fuel level decreases. When the needle reaches “E”, approximately 3.0 L (0.79 US gal) (0.66 Imp.gal) remain in the fuel tank. If this occurs, refuel as soon as possible. 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 completely.

• The fuel gauge does not indicate the correct fuel level for the first 5 km/h (3 mi/h) after refueling.

Odometer, tripmeter, and clock modes

1. Odometer/tripmeter/fuel reserve tripmeter/clock

Push the “SELECT” switch to switch the display between the odometer mode “ODO”, the tripmeter modes “TRIP 1” and “TRIP 2” and the clock mode in the following order: ODO → TRIP 1 → TRIP 2 → Clock → ODO If the fuel level warning light comes on, the odometer display will automatically change to the fuel reserve tripmeter mode “F-TRIP” and start counting the distance traveled from that point. In that case, push the “SELECT” switch to switch the display between the various tripmeter, 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- 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 the prior mode after refueling and traveling 5 km (3 mi).

Clock mode

1. Clock

1-5

FEATURES

To set the clock:

1. Push the “SELECT” switch to change the display to the clock mode.

2. Push the “SELECT” and “RESET” switches together for at least two seconds.

3. When the hour digits start flashing, push the “RESET” switch to set the hours.

4. Push the “SELECT” switch, and the minute digits will start flashing.

5. Push the “RESET” switch to set the minutes.

6. Push the “SELECT” switch and then release it to start the clock.

Self-diagnosis device

This model is equipped with a self-diagnosis device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on, and then the odometer/tripmeter/clock display will indicate a two-digit error code (e.g., 12, 13, 14). If the odometer/tripmeter/clock display indicates any error codes, note the code number, and then check the vehicle. Refer to “FUEL INJECTION SYSTEM” on page 7-27.

EC1D71018

CAUTION:

If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage.

Select the brightness control mode as follows.

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. Item number “1” is displayed.

1. Multi-function meter unit panel

2. Item number

3. Brightness level

4. Adjust the multi-function meter unit panel brightness level by pushing the “RESET” switch.

5. Push the “SELECT” switch to select the LCD. Item number “2” is displayed. Adjust the LCD brightness level by pushing the “RESET” switch.

Brightness control mode

1. Multi-function meter unit panel

2. LCD

3. Speedometer needle

4. Tachometer needle

5. Fuel gauge needle

The brightness can be adjusted for the following:

• the multi-function meter unit panel (item number “1”)

• the LCD (item number “2”)

• the speedometer, tachometer, and the fuel gauge needles (item number “3”)

1. LCD

2. Item number

3. Brightness level

6. Push the “SELECT” switch to select the speedometer, tachometer, and the fuel gauge needles. Item number “3” is displayed. Adjust the brightness level of the speedometer, tachometer, and the fuel gauge needles by pushing the “RESET” switch.

1-6

2 3

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 return to the prior mode.

EAS1D77010

INSTRUMENT FUNCTIONS (for XV19CS(C)/ XV19C(C))

FEATURES

• a fuel reserve tripmeter (which shows the distance traveled on the fuel reserve)

• a clock

• a self-diagnosis device

• a brightness control mode

NOTE:

Be sure to turn the key to “ON” before using the “SELECT” and reset switches, except for setting

the brightness control mode.

1. “SELECT” switch

Multi-function meter unit

1. Speedometer

2. Odometer/tripmeter/fuel reserve 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)

• a fuel gauge

• an odometer (which shows the total distance

traveled)

• two tripmeters (which show the distance traveled since they were last set to zero)

120

100

km/h

MPH

140

160

100

110

180

12 0

200

13 0

220

14 0

1. Reset switch

Speedometer

1. Speedometer

When the key is turned to “ON”, the speedometer needle will sweep once across the speed range and then return to zero in order to test the electrical circuit.

1-7

FEATURES

Fuel gauge

1. Fuel gauge

NOTE:

• Do not allow the fuel tank to empty itself completely.

• The fuel gauge does not indicate the correct fuel level for the first 5 km/h (3 mi/h) after refueling.

Operation of the fuel gauge and fuel level warning light

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 range, which includes the sub-fuel tank. (The fuel sender detection range is from the full level [approximately 16 L (4.23 US gal) (3.52 Imp.gal)] to the half-full level [approximately 8 L (2.11 US gal) (1.72 Imp.gal)].) For the fuel level range that the fuel sender is not able to detect, the fuel level is calculated using the distance traveled and preset fuel consumption values according to vehicle speed. (The estimation range is from 0 L to the half-full level [approximately 8 L (2.11 US gal) (1.72 Imp.gal)].) The fuel gauge operates according to the fuel sender in the detection range “a” and according to the estimation in the range “b”. When the fuel level reaches the fuel level warning light activation point “e”, the warning light is activated by the fuel pump thermistor in the subfuel tank. Operation of the fuel gauge and fuel level warning light after refueling If the fuel level remains in the estimation range “b” after refueling, the fuel gauge will not operate. However, if the fuel level reaches the fuel sender detection range “a”, the fuel gauge will operate and the fuel level will be displayed. The fuel level warning light will go off when the fuel level is above the activation point “e”, even if the fuel level remains in the estimation range.

a. Fuel sender detection range

1-8

FEATURES

Odometer, tripmeters, fuel reserve tripmeter and clock

1. Odometer/tripmeter/fuel reserve tripmeter/clock

Push the “SELECT” switch to change the display between the odometer mode “ODO”, the tripmeter modes “TRIP A” and “TRIP B” in the following order: ODO → TRIP A → TRIP B → ODO If the fuel level warning light comes on, the odometer display will automatically change to the fuel reserve tripmeter mode “F-TRIP” and start counting the distance traveled from that point. In that case, push the “SELECT” switch to change the display between the various tripmeter and odometer modes in the following order: 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 automatically, and the display will return to the prior mode after refueling and traveling 5 km (3 mi).

1. Push the “SELECT” and reset switches together 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 device for various electrical circuits. If any of those circuits are defective, the engine trouble warning light will come on, and then the odometer/tripmeter/clock display will indicate a two-digit error code. If the odometer/tripmeter/clock display indicates any error codes, note the code number, and then have a Yamaha dealer check the vehicle.

ECA1D77001

CAUTION:

If the display indicates an error code, the vehicle should be checked as soon as possible in order to avoid engine damage.

Brightness control mode

To set the clock

1. 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.

1-9

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 return to the prior mode.

FEATURES

1-10

EAS20180

IMPORTANT INFORMATION

EAS20190

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

2. Use only the proper tools and cleaning equipment. 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 assembly.

IMPORTANT INFORMATION

EAS20210

GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EAS20200

REPLACEMENT PARTS

Use only genuine Yamaha parts for all replacements. 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. Oil

2. Lip

3. Spring

4. Grease

EAS20220

LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates “1” and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

1-11

EAS20230

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manufacturer’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 appropriate.

ECA13300

CAUTION:

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

IMPORTANT INFORMATION

EAS20240

CIRCLIPS

Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always 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

EAS20250

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1. Disconnect:

• Lead

• Coupler

• Connector

2. Check:

• Lead

• Coupler

• Connector

Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times.

CHECKING THE CONNECTIONS

Pocket tester

90890-03112

NOTE:

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3).

• As a quick remedy, use a contact revitalizer available at most part stores.

Analog pocket tester

YU-03112-C

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-”.

Tool name/Tool No. Illustration

Pocket tester 90890-03112 Analog pocket tester YU-03112-C

Thickness gauge 90890-03180 Feeler gauge set YU-26900-9

Tappet adjusting tool (4 mm) 90890-04133 Six piece tappet set YM-A5970

Reference

pages

1-13, 5-84, 7-73, 7-74, 7-75, 7-79, 7-80, 7-81, 7-82, 7-83, 7-84, 7-85, 7-86, 7-87, 7-88, 7-89, 7-91

3-6, 5-65

3-6, 3-7

Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456

YM-A5970

ø9ø8 ø10

ø3 ø4

3-7

YU-44456

1-14

SPECIAL TOOLS

Tool name/Tool No. Illustration

Timing light 90890-03141 Inductive clamp timing light YU-03141

Oil filter wrench 90890-01426 YU-38411

Belt tension gauge 90890-03170 Rear drive belt tension gauge YM-03170

Steering nut wrench 90890-01403 Spanner wrench YU-33975

Reference

pages

3-10

3-12

3-26

3-27, 4-81

Damper rod holder 90890-01460

T-handle 90890-01326 T-handle 3/8" drive 60 cm long YM-01326

Fork seal driver 90890-01442 Adjustable fork seal driver (36–46 mm) YM-01442

Pivot shaft wrench 90890-01485 Frame mount insert wrench YM-01485

4-71, 4-73

4-73, 4-74

5-15

Valve spring compressor 90890-04019 YM-04019

5-42, 5-47

1-15

SPECIAL TOOLS

Tool name/Tool No. Illustration

Valve guide remover (ø6) 90890-04064 Valve guide remover (6.0 mm) YM-04064-A

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

Valve guide reamer (ø6) 90890-04066 Valve guide reamer (6.0 mm) YM-04066

Piston pin puller set 90890-01304 Piston pin puller YU-01304

Reference

pages

5-43

5-49

Universal clutch holder 90890-04086 YM-91042

Sheave holder 90890-01701 Primary clutch holder YS-01880-A

YU-01304

5-64, 5-69

5-64, 5-68, 5-79, 5-80

1-16

SPECIAL TOOLS

Tool name/Tool No. Illustration

Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®)

Rotor puller 90890-01080 Stator rotor puller YM-01080-A

Vacuum/pressure pump gauge set 90890-06756 Mityvac brake bleeding tool YS-42423

Pressure gauge 90890-03153 YU-03153

Reference

pages

5-70, 5-80, 5-98

5-79

6-16

Fuel pressure adapter 90890-03176 YM-03176

Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927

Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487

6-16

7-83

1-17

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................2-1

ENGINE SPECIFICATIONS ............................................................................2-3

CHASSIS SPECIFICATIONS ........................................................................2-11

ELECTRICAL SPECIFICATIONS .................................................................2-16

TIGHTENING TORQUES ..............................................................................2-20

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

GENERAL SPECIFICATIONS

Model

Model XV19SX 1D77 (USA)

XV19SXC 1D78 (California) XV19SX 1D79 (CDN) XV19MX 4D57 (USA) XV19MXC 4D58 (California) XV19MX 4D59 (CDN) XV19CTSX 2C57 (USA) XV19CTSXC 2C58 (California) XV19CTSX 2C59 (CDN) XV19CTMX 4P17 (USA) XV19CTMXC 4P18 (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) XV19CS(C)/ XV19C(C): 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) XV19CS(C)/ XV19C(C): 1165 mm (45.9 in)

Seat height XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C): 735 mm (28.9 in) XV19CS(C)/ XV19C(C): 695 mm (27.4 in)

Wheelbase XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C): 1715 mm (67.5 in) XV19CS(C)/ XV19C(C): 1799 mm (70.8 in)

2-1

GENERAL SPECIFICATIONS

Ground clearance XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C): 155 mm (6.10 in) XV19CS(C)/ XV19C(C): 146 mm (5.75 in)

Minimum turning radius XV19S(C)/ XV19M(C)/ XV19CTS(C)/

XV19CTM(C): 3480 mm (137.0 in) XV19CS(C)/ XV19C(C): 3500 mm (137.8 in)

Weight

With oil and fuel XV19S(C)/ XV19M(C):

340.0 kg (750 lb) XV19CTS(C)/ XV19CTM(C):

364.0 kg (802 lb) XV19CS(C)/ XV19C(C):

331.0 kg (730 lb)

Maximum load XV19S(C)/ XV19M(C):

210 kg (463 lb) XV19CTS(C)/ XV19CTM(C): 186 kg (410 lb) XV19CS(C)/ XV19C(C): 204 kg (450 lb)

2-2

ENGINE SPECIFICATIONS

EAS20290

ENGINE SPECIFICATIONS

Engine

Engine type Air cooled 4-stroke, OHV Displacement 1854.0 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 100.0 × 118.0 mm (3.94 × 4.65 in) Compression ratio 9.48 :1 Starting system Electric starter

Fuel

Recommended fuel Premium 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) XV19CS(C)/ XV19C(C):

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) XV19CS(C)/ XV19C(C):

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

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

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Yamaha XV19SX(C), XV19MX(C), XV19CTSX(C), XV19CTMX(C), XV19CSX(C) Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual