YAMAHA XV19CTMW(C), XV19CTSW(C), XV19CTW(C), XV19SW(C), XV19W(C) SERVICE MANUALS 1D7

Yamaha Service Manual

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XV19SW(C)

XV19W(C)

XV19MW(C)

XV19CTSW(C)

XV19CTW(C)

XV19CTMW(C)

SERVICE MANUAL

LIT-11616-20-40

1D7-28197-11

EAS20050

XV19SW(C)/XV19W(C)/XV19MW(C)/

XV19CTSW(C)/XV19CTW(C)/XV19CTMW(C)

SERVICE MANUAL

©2006 by Yamaha Motor Corporation, U.S.A. First edition, July 2006

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-11616-20-40

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.

WARNING

CAUTION:

NOTE:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator, a bystander or a person checking or repairing the vehicle.

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 is shown at the top of each page “1”.

•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.

1		2		3

4	5	6
		T
		.
		R
7	8

9				10						11
		E						G						M
12				13						14
		B						LS						M
15										16

LT New

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.Wheel-bearing grease

13.Lithium-soap-based grease

14.Molybdenum-disulfide grease

15.Apply locking agent (LOCTITE®)

16.Replace the part

EAS20110

TABLE OF CONTENTS

GENERAL INFORMATION	1

SPECIFICATIONS	2

PERIODIC CHECKS AND ADJUSTMENTS 3

CHASSIS

ENGINE

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

4

5

6

7

8

GENERAL INFORMATION

	IDENTIFICATION ............................................................................................	1-1
	VEHICLE IDENTIFICATION NUMBER	1-1
				1
	MODEL LABEL .........................................................................................	1-1
	FEATURES	1-2
	OUTLINE OF THE FI SYSTEM	1-2
	FI SYSTEM ...............................................................................................	1-3
	INSTRUMENT FUNCTIONS.....................................................................	1-4
	IMPORTANT INFORMATION .........................................................................	1-8
	PREPARATION FOR REMOVAL AND DISASSEMBLY ..........................	1-8
	REPLACEMENT PARTS ..........................................................................	1-8
	GASKETS, OIL SEALS AND O-RINGS ....................................................	1-8
	LOCK WASHERS/PLATES AND COTTER PINS.....................................	1-8
	BEARINGS AND OIL SEALS....................................................................	1-9
	CIRCLIPS..................................................................................................	1-9
	CHECKING THE CONNECTIONS................................................................	1-10
	SPECIAL TOOLS..........................................................................................	1-11

IDENTIFICATION

EAS20130

IDENTIFICATION

EAS20140

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped into the right side of the steering head pipe.

1

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

1-1

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.

1	2			3		4				5 6 7 8								9 10				11	12

	21	20 16	19	18	17	16 15	14	13
1.	Air temperature sensor					15. Lean angle sensor
2.	ISC (idle speed control) unit					16. Spark plug
3.	Cylinder-#2 intake air pressure sensor					17. Injector #1
4.	Engine temperature sensor					18. Crankshaft position sensor
5.	Cylinder-#1 right ignition coil					19. Injector #2
6.	Throttle position sensor					20. Cylinder-#2 right ignition coil
7.	Cylinder-#1 left ignition coil					21. Cylinder-#2 left ignition coil

8.Cylinder-#1 intake air pressure sensor

9.Fuel pump

10.ECU (electronic control unit)

11.Relay unit (fuel pump relay)

12.EXUP servo motor

13.Speed sensor

14.O2 sensor

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 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	2	C	8
	A			5
			3
	#2 #1
			4	9
	15			10
		B
			14
		13		11
				12

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.O2 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

FEATURES

ET1D71036

INSTRUMENT FUNCTIONS

Multi-function meter unit

EW1D71008

WARNING

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

1

4

2

3

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

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

2

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

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

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 “SELECT” 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.

Brightness control mode

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

2

3

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.

1

3

4

5

2

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 2

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

FEATURES

1

2

3

4

5

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.

1-7

IMPORTANT INFORMATION

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 1-11.

3.When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly.

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.

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.

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.

1-8

IMPORTANT INFORMATION

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.

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.

1-9

CHECKING THE CONNECTIONS

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.

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)

Pocket tester 90890-03112

Analog pocket tester YU-03112-C

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.

1-10

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	Reference
			pages
	Pocket tester		1-10, 5-79,
	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,
			7-90, 7-91
	Thickness gauge		3-6, 5-61
	90890-03180
	Feeler gauge set
	YU-26900-9
	Tappet adjusting tool (4 mm)		3-6, 3-7
	90890-04133
	Valve adjustment wrench 3 mm & 4 mm
	YM-08035-A

Vacuum gauge	3-7
90890-03094
Carburetor synchronizer
YU-44456
	YU-44456

1-11

		SPECIAL TOOLS
Tool name/Tool No.	Illustration		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			3-24
90890-03170
Rear drive belt tension gauge
YM-03170
Steering nut wrench			3-26, 4-71
90890-01403
Spanner wrench
YU-33975
Damper rod holder			4-64, 4-66
90890-01460
T-handle			4-64, 4-66
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver			4-66, 4-67
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442
Pivot shaft wrench			5-12
90890-01485
Frame mount insert wrench
YM-01485
Valve spring compressor			5-39, 5-44
90890-04019
YM-04019

1-12

			SPECIAL TOOLS
	Tool name/Tool No.	Illustration	Reference
			pages
	Valve guide remover (ø6)		5-40
	90890-04064
	Valve guide remover (6.0 mm)
	YM-04064-A
	Valve guide installer (ø6)		5-40
	90890-04065
	Valve guide installer (6.0 mm)
	YM-04065-A
	Valve guide reamer (ø6)		5-40
	90890-04066
	Valve guide reamer (6.0 mm)
	YM-04066
	Piston pin puller set		5-46
	90890-01304
	Piston pin puller
	YU-01304
		YU-01304

Universal clutch holder	5-60, 5-65
90890-04086
YM-91042

Sheave holder	5-60, 5-64,
90890-01701	5-74, 5-75
Primary clutch holder
YS-01880-A
Yamaha bond No. 1215	5-66, 5-76,
90890-85505	5-93
(Three Bond No.1215®)

1-13

			SPECIAL TOOLS
	Tool name/Tool No.	Illustration	Reference
			pages
	Rotor puller		5-74
	90890-01080
	Stator rotor puller
	YM-01080-A
	Vacuum/pressure pump gauge set		6-12
	90890-06756
	Pressure gauge		6-12
	90890-03153
	Fuel pressure adapter		6-12
	90890-03176
	YM-03176
	Digital circuit tester		6-12
	90890-03174
	Model 88 Multimeter with tachometer
	YU-A1927
	Ignition checker		7-83
	90890-06754
	Opama pet-4000 spark checker
	YM-34487

1-14

SPECIAL TOOLS

1-15

SPECIFICATIONS

GENERAL SPECIFICATIONS ........................................................................	2-1
ENGINE SPECIFICATIONS............................................................................	2-2
CHASSIS SPECIFICATIONS........................................................................	2-10
ELECTRICAL SPECIFICATIONS	2-13	2
TIGHTENING TORQUES..............................................................................	2-16
.........................GENERAL TIGHTENING TORQUE SPECIFICATIONS	2-16
ENGINE TIGHTENING TORQUES.........................................................	2-17
CHASSIS TIGHTENING TORQUES.......................................................	2-22
LUBRICATION POINTS AND LUBRICANT TYPES ....................................	2-27
ENGINE ..................................................................................................	2-27
CHASSIS ................................................................................................	2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS ...................................	2-31
ENGINE OIL LUBRICATION CHART .....................................................	2-31
LUBRICATION DIAGRAMS ....................................................................	2-33
CABLE ROUTING.........................................................................................	2-45

	GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model	XV19SW 1D74 (USA)
	XV19SW 1D76 (CDN)
	XV19SWC 1D75 (California)
	XV19W 4D45 (USA)
	XV19W 4D47 (CDN)
	XV19WC 4D46 (California)
	XV19MW 4D54 (USA)
	XV19MW 4D56 (CDN)
	XV19MWC 4D55 (California)
	XV19CTSW 2C54 (USA)
	XV19CTSW 2C56 (CDN)
	XV19CTSWC 2C55 (California)
	XV19CTW 4P04 (USA)
	XV19CTW 4P06 (CDN)
	XV19CTWC 4P05 (California)
	XV19CTMW 4P14 (USA)
	XV19CTMW 4P16 (CDN)
	XV19CTMWC 4P15 (California)
Dimensions
Overall length	2580 mm (101.6 in)
Overall width	1100 mm (43.3 in)
Overall height	XV19S(C)/XV19(C)/XV19M(C):
	1100 mm (43.3 in)
	XV19CTS(C)/XV19CT(C)/XV19CTM(C):
	1515 mm (59.6 in)
Seat height	735 mm (28.9 in)
Wheelbase	1715 mm (67.5 in)
Ground clearance	155 mm (6.10 in)
Minimum turning radius	3480 mm (137.0 in)
Weight
With oil and fuel	XV19S(C)/XV19(C)/XV19M(C):
	340.0 kg (750 lb)
	XV19CTS(C)/XV19CT(C)/XV19CTM(C):
	364.0 kg (802 lb)
Maximum load	XV19S(C)/XV19(C)/XV19M(C):
	210 kg (463 lb)
	XV19CTS(C)/XV19CT(C)/XV19CTM(C):
	186 kg (410 lb)

2-1

	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	17.0 L (4.49 US gal) (3.74 Imp.gal)
Fuel reserve amount	3.0 L (0.79 US gal) (0.66 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)
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

2-2

					ENGINE SPECIFICATIONS
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)
Limit	35.850 mm (1.4114 in)

2-3

								ENGINE SPECIFICATIONS
					A
		B
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)
Limit								2.0 mm (0.08 in)
				C
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 (exhaust)								1.15–1.45 mm (0.0453–0.0571 in)
Limit								0.4 mm (0.02 in)
					D
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)

2-4