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

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Page 1

Yamaha Service Manual

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Page 2

XV19SW(C)

XV19W(C)

XV19MW(C)

XV19CTSW(C)

XV19CTW(C)

XV19CTMW(C)

SERVICE MANUAL

LIT-11616-20-40 1D7-28197-11

Page 3

EAS20050

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

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

SERVICE MANUAL

First edition, July 2006

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

Page 4

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.

Page 5

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.

Page 6

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.Wheel-bearing grease

13.Lithium-soap-based grease

14.Molybdenum-disulfide grease

15.Apply locking agent (LOCTITE

16.Replace the part

)

91011

12 13 14

15 16

New

Page 7

Page 8

EAS20110

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

CHASSIS

ENGINE

FUEL SYSTEM

ELECTRICAL SYSTEM

TROUBLESHOOTING

Page 9

Page 10

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..................................................................... 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

Page 11

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

Page 12

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.

2021

1. Air temperature sensor

2. ISC (idle speed control) unit

3. Cylinder-#2 intake air pressure sensor

4. Engine temperature sensor

5. Cylinder-#1 right ignition coil

6. Throttle position sensor

7. Cylinder-#1 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.O

sensor

345678 910 11 12

14 1316 19 18 17 16 15

15.Lean angle sensor

16.Spark plug

17.Injector #1

18.Crankshaft position sensor

19.Injector #2

20.Cylinder-#2 right ignition coil

21.Cylinder-#2 left ignition coil

1-2

Page 13

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

Page 14

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.

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

Page 15

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

Page 16

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

4 5

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

Page 17

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.

FEATURES

1-7

Page 18

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 “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.

1-8

Page 19

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.

1-9

Page 20

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)

1-10

Page 21

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 Valve adjustment wrench 3 mm & 4 mm YM-08035-A

Reference

pages

1-10, 5-79, 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, 7-90, 7-91

3-6, 5-61

3-6, 3-7

Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456

3-7

YU-44456

1-11

Page 22

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

3-24

3-26, 4-71

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

4-64, 4-66

4-66, 4-67

5-12

Valve spring compressor 90890-04019 YM-04019

5-39, 5-44

1-12

Page 23

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

5-40

5-46

Universal clutch holder 90890-04086 YM-91042

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

Yamaha bond No. 1215 90890-85505

(Three Bond No.1215

YU-01304

5-60, 5-65

5-60, 5-64, 5-74, 5-75

5-66, 5-76, 5-93

)

1-13

Page 24

SPECIAL TOOLS

Tool name/Tool No. Illustration

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

Vacuum/pressure pump gauge set 90890-06756

Pressure gauge 90890-03153

Fuel pressure adapter 90890-03176 YM-03176

Reference

pages

5-74

6-12

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

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

6-12

7-83

1-14

Page 25

SPECIAL TOOLS

1-15

Page 26

SPECIFICATIONS

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

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

CHASSIS SPECIFICATIONS........................................................................ 2-10

ELECTRICAL SPECIFICATIONS................................................................. 2-13

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

Page 27

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

Page 28

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

Page 29

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

Page 30

ENGINE SPECIFICATIONS

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)

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)

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)

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

Page 31

ENGINE SPECIFICATIONS

Valve guide inside diameter (exhaust) 6.000–6.012 mm (0.2362–0.2367 in) 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)

2-5

Page 32

ENGINE SPECIFICATIONS

Valve push rod runout 0.3 mm (0.012 in)

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)

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)

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 Dimensions (B × T) 1.20 × 4.00 mm (0.05 × 0.16 in)

End gap (installed) 0.45–0.60 mm (0.0177–0.0236 in) 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)

2-6

Page 33

ENGINE SPECIFICATIONS

Oil ring

Dimensions (B × T) 2.50 × 3.40 mm (0.10 × 0.13 in)

End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in)

Connecting rod

Oil clearance (using plastigauge 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)

) 0.050–0.074 mm (0.0020–0.0029 in)

Journal oil clearance (using plastigauge 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) Plate quantity 1 pcs Clutch plate thickness 1.90–2.10 mm (0.075–0.083 in) Plate quantity 10 pcs 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

) 0.030–0.060 mm (0.0012–0.0024 in)

2-7

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ENGINE SPECIFICATIONS

Primary reduction system Spur gear Primary reduction ratio 72/51 (1.412) Secondary reduction system Belt drive Secondary reduction ratio 70/31 (2.258) 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 XV19M/XV19S/XV19/XV19CTM/

XV19CTS/XV19CT: 1D71 00 XV19MC/XV19SC/XV19C/XV19CTMC/ XV19CTSC/XV19CTC: 1D72 10

Throttle valve size #100

Throttle position sensor

Resistance 4.0–6.0 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)

2-8

Page 35

ENGINE SPECIFICATIONS

Idling condition

Engine idling speed 850–950 r/min Intake vacuum 31.3–35.3 kPa (9.3–10.4 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)

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Page 36

CHASSIS SPECIFICATIONS

EAS20300

CHASSIS SPECIFICATIONS

Chassis

Frame type Double cradle Caster angle 31.20 ° Trail 152.0 mm (5.98 in)

Front wheel

Wheel type Cast wheel Rim size 18M/C × MT4.00 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 17M/C × MT5.50 Rim material Aluminum Wheel travel 110.0 mm (4.33 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 130/70R18M/C 63H Manufacturer/model DUNLOP/D251F Manufacturer/model BRIDGESTONE/G851 RADIAL G Wear limit (front) 1.0 mm (0.04 in)

Rear tire

Type Tubeless Size 190/60R17M/C 78H Manufacturer/model DUNLOP/D251 Manufacturer/model BRIDGESTONE/G850 RADIAL G 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)/XV19(C)/XV19M(C):

90–210 kg (198–463 lb)

XV19CTS(C)/XV19CT(C)/XV19CTM(C):

90–186 kg (198–410 lb)

Front 250 kPa (36 psi) (2.50 kgf/cm²) Rear 280 kPa (41 psi) (2.80 kgf/cm²)

High-speed riding

Front 250 kPa (36 psi) (2.50 kgf/cm²) Rear 280 kPa (41 psi) (2.80 kgf/cm²)

2-10

Page 37

CHASSIS SPECIFICATIONS

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) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 5.5 mm (0.22 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 14.00 mm (0.55 in) Caliper cylinder inside diameter 27.00 mm (1.06 in) Caliper cylinder inside diameter 30.23 mm (1.19 in) Recommended fluid DOT 4

Rear brake

Type Single disc brake Operation Right foot operation Brake pedal position 110.0 mm (4.33 in) Rear disc brake

Disc outside diameter × thickness 320.0 × 6.0 mm (12.60 × 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) Limit 0.8 mm (0.03 in) Brake pad lining thickness (outer) 5.8 mm (0.23 in) Limit 0.8 mm (0.03 in) Master cylinder inside diameter 12.7 mm (0.50 in) Caliper cylinder inside diameter 41.30 mm (1.63 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 273.9 mm (10.78 in) Limit 268.4 mm (10.57 in) Collar length 230.0 mm (9.06 in) Installed length 268.9 mm (10.59 in) Spring rate K1 10.0 N/mm (57.1 lb/in) (1.02 kgf/mm) Spring stroke K1 0.0–30.0 mm (0.00–1.18 in) Spring rate K2 12.0 N/mm (68.5 lb/in) (1.22 kgf/mm) Spring stroke K2 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

2-11

Page 38

CHASSIS SPECIFICATIONS

Recommended oil Fork oil 10WT Quantity 571.0 cm³ (19.31 US oz) (20.10 Imp.oz) Level 124.0 mm (4.88 in)

Rear suspension

Type Swingarm (link suspension) Spring/shock absorber type Coil spring/gas-oil damper Rear shock absorber assembly travel 50.0 mm (1.97 in) Spring free length 180.0 mm (7.09 in) Limit 176.4 mm (6.94 in) Installed length XV19S(C)/XV19(C)/XV19M(C):

171.0 mm (6.73 in)

XV19CTS(C)/XV19CT(C)/XV19CTM(C):

165.0 mm (6.50 in) Spring rate K1 176.50 N/mm (1007.82 lb/in) (18.00 kgf/mm) Spring stroke K1 0.0–50.0 mm (0.00–1.97 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 162.0 mm (6.38 in) Standard XV19S(C)/XV19(C)/XV19M(C):

171.0 mm (6.73 in)

XV19CTS(C)/XV19CT(C)/XV19CTM(C):

165.0 mm (6.50 in)

Maximum 171.0 mm (6.73 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)

2-12

Page 39

ELECTRICAL SPECIFICATIONS

EAS20310

ELECTRICAL SPECIFICATIONS

Voltage

System voltage 12 V

Ignition system

Ignition system Transistorized coil ignition (digital) Advancer type Electrical Ignition timing (B.T.D.C.) 10.0 °/900 r/min

Engine control unit

Model/manufacturer F008T83271/MITSUBISHI

Ignition coil

Model/manufacturer 2JN/MORIC 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 12 V, 51.0 W × 1 High beam headlight 12 V, 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 12 V, 5.0 W Meter lighting LED

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ELECTRICAL SPECIFICATIONS

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/MORIC 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 Turn signal blinking frequency 75.0–95.0 cycles/min Wattage 21(23) W × 2 + LED × 2

Fuel gauge

Model/manufacturer 1D7/YAMAHA 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

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ELECTRICAL SPECIFICATIONS

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 10.0 A Signaling system fuse 10.0 A Ignition fuse 25.0 A Auxiliary DC connector fuse 3.0 A ECU fuse 10.0 A Fuel injection system fuse 15.0 A Backup fuse 10.0 A Reserve fuse 25.0 A Reserve fuse 20.0 A Reserve fuse 15.0 A Reserve fuse 10.0 A Reserve fuse 3.0 A

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EAS20320

TIGHTENING TORQUES

EAS20330

GENERAL TIGHTENING TORQUE SPECIFICATIONS

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

TIGHTENING TORQUES

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

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EAS20340

ENGINE TIGHTENING TORQUES

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Cylinder head nut M12 8 60 Nm (6.0 m·kg, 43 ft·lb)

Cylinder head stud bolt (exhaust pipe)

M8 4 15 Nm (1.5 m·kg, 11 ft·lb)

Spark plug M12 4 18 Nm (1.8 m·kg, 13 ft·lb)

Engine temperature sensor — 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)

Connecting rod bolt (1st) M8 4 15 Nm (1.5 m·kg, 11 ft·lb)

Connecting rod bolt (final) M8 4 Specified angle 125–135°

Right balancer driven gear bolt M10 1 40 Nm (4.0 m·kg, 29 ft·lb)

Left balancer drive gear bolt M10 1 40 Nm (4.0 m·kg, 29 ft·lb)

See

NOTE.

See

NOTE.

Left balancer driven gear housing screw

M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)

Left balancer weight bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Left balancer idle gear shaft bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft driven gear bolt M10 1 60 Nm (6.0 m·kg, 43 ft·lb)

Camshaft drive gear bolt M10 1 60 Nm (6.0 m·kg, 43 ft·lb)

Front cylinder camshaft gear bolt M10 1 40 Nm (4.0 m·kg, 29 ft·lb)

Locknut (rocker arm adjusting screw)

M7 4 20 Nm (2.0 m·kg, 14 ft·lb)

Valve lifter case bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

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 M8 1 18 Nm (1.8 m·kg, 13 ft·lb)

Oil filter bracket bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pipe bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil delivery pipe 2 bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Engine oil pump driven gear stopper bolt

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

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)

2-17

Page 44

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Oil pipe 2 bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pipe 4 bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump housing cover 1 screw (crankcase)

Oil pump housing cover 2 screw (crankcase)

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Throttle body joint clamp screw M5 2 3 Nm (0.3 m·kg, 2.2 ft·lb)

Pressure 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 exhaust pipe bolt

Rear exhaust pipe and muffler bolt

M8 1 20 Nm (2.0 m·kg, 14 ft·lb)

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 muffler bracket bolt M8 3 29 Nm (2.9 m·kg, 21 ft·lb)

Muffler bracket and frame bolt M10 2 53 Nm (5.3 m·kg, 38 ft·lb)

sensor

M18 1 44 Nm (4.4 m·kg, 32 ft·lb)

Crankcase stud bolt M12 8 See NOTE.

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 crankcase)

M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankcase stud bolt M10 1 See NOTE.

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)

Bearing housing bolt (torque limiter)

M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil gallery bolt M8 4 20 Nm (2.0 m·kg, 14 ft·lb)

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)

Crankshaft position sensor lead holder screw

M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)

2-18

Page 45

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Clutch cover damper plate screw M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft cover bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)

Generator damper cover bolt M5 3 5 Nm (0.5 m·kg, 3.6 ft·lb)

Engine oil filler plug M20 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Camshaft sprocket cover plate bolt

Oil baffle plate bolt (right crankcase)

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch cover plate bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

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 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Clutch damper cover plate bolt M5 3 5 Nm (0.5 m·kg, 3.6 ft·lb)

Clutch damper cover 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)

Generator rotor bolt M12 1 80 Nm (8.0 m·kg, 58 ft·lb)

Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Primary drive gear bolt M12 1 100 Nm (10.0 m·kg, 72 ft·lb)

Clutch boss nut M20 1 105 Nm (10.5 m·kg, 75 ft·lb)

Stake

Clutch spring plate retainer bolt M6 6 8 Nm (0.8 m·kg, 5.8 ft·lb)

Bleed screw (clutch release cylinder)

M8 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

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 screw M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

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)

Middle drive gear nut M22 1 140 Nm (14.0 m·kg, 100 ft·lb)

Transfer gear case oil pump assembly nut

Transfer gear case oil pump assembly bolt

Oil pump housing screw (transfer gear case)

M10 1 40 Nm (4.0 m·kg, 29 ft·lb)

M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb)

Stake

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)

2-19

Page 46

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Dipstick joint bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Drive pulley case bolt M10 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)

Oil pipe 5 bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Transfer gear case cover plate bolt

M6 3 5 Nm (0.5 m·kg, 3.6 ft·lb)

Transfer gear case cover bolt M6 12 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil tank cover bolt M6 15 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil tank bracket bolt 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)

Stopper lever bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankshaft position sensor screw M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Neutral switch screw M6 2 4 Nm (0.4 m·kg, 2.9 ft·lb)

Stator coil screw M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

Neutral switch lead clamp screw M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Speed sensor bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil cooler bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Oil cooler bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Oil cooler hose bolt 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)

Clutch pipe joint nut M10 1 19 Nm (1.9 m·kg, 13 ft·lb)

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).

2-20

Page 47

Cylinder head tightening sequence:

TIGHTENING TORQUES

A. Front cylinder B. Rear cylinder

2-21

Page 48

EAS20350

CHASSIS TIGHTENING TORQUES

TIGHTENING TORQUES

Item

Engine mounting bolt (left upper side)

Engine mounting bolt (right upper side)

Engine mounting nut (rear upper side)

Thread

size

Q’ty Tightening torque Remarks

M12 2 66 Nm (6.6 m·kg, 48 ft·lb)

M12 2 59 Nm (5.9 m·kg, 43 ft·lb)

M12 1 98 Nm (9.8 m·kg, 71 ft·lb)

Engine mounting spacer bolt M18 1 18 Nm (1.8 m·kg, 13 ft·lb)

Engine bracket bolt (left upper side)

Engine bracket bolt (right upper side)

Engine bracket nut (rear upper side)

Engine mounting nut (front upper side)

Engine mounting nut (rear lower side)

Engine mounting nut (front lower side)

Engine bracket nut (front upper side)

Engine cross-member bracket bolt

M10 2 53 Nm (5.3 m·kg, 38 ft·lb)

M12 1 98 Nm (9.8 m·kg, 71 ft·lb)

M12 1 105 Nm (10.5 m·kg, 75 ft·lb)

M10 4 53 Nm (5.3 m·kg, 38 ft·lb)

M10 2 30 Nm (3.0 m·kg, 22 ft·lb)

Engine bracket nut (left rear lower side)

Engine bracket bolt (right rear lower side)

Transfer gear case bracket and transfer gear case bolt

Transfer gear case bracket and frame bolt

M10 3 58 Nm (5.8 m·kg, 42 ft·lb)

M10 2 53 Nm (5.3 m·kg, 38 ft·lb)

M10 2 63 Nm (6.3 m·kg, 45 ft·lb)

M10 2 53 Nm (5.3 m·kg, 38 ft·lb)

Cylinder-#1 ignition coil bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Cylinder-#2 ignition coil bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Lean angle sensor bolt M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb)

Horn bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

ISC (idle speed control) unit bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

ISC (idle speed control) unit bracket bolt

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Pivot shaft nut M18 1 125 Nm (12.5 m·kg, 90 ft·lb)

Relay arm nut (relay arm and swingarm)

M12 1 59 Nm (5.9 m·kg, 43 ft·lb)

2-22

Page 49

TIGHTENING TORQUES

Item

Relay arm nut (relay arm and connecting arm)

Rear shock absorber assembly nut (rear side)

Rear shock absorber assembly nut (front side)

Thread

size

Q’ty Tightening torque Remarks

M12 1 59 Nm (5.9 m·kg, 43 ft·lb)

M10 1 40 Nm (4.0 m·kg, 29 ft·lb)

M12 1 59 Nm (5.9 m·kg, 43 ft·lb)

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 M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

Headlight cover bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Headlight bracket and throttle cable guide bolt

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Headlight body bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)

Steering stem nut M28 1 115 Nm (11.5 m·kg, 85 ft·lb)

Upper handlebar holder bolt M8 4 28 Nm (2.8 m·kg, 20 ft·lb)

Lower ring nut (initial tightening torque)

M30 1 52 Nm (5.2 m·kg, 37 ft·lb)

See

NOTE.

Lower ring nut (final tightening torque)

Hose guide and lower handlebar holder nut

Front brake master cylinder holder bolt

Front brake hose union bolt (front brake master cylinder side)

M30 1 18 Nm (1.8 m·kg, 13 ft·lb)

M10 2 32 Nm (3.2 m·kg, 23 ft·lb)

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

M10 2 30 Nm (3.0 m·kg, 22 ft·lb)

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 M10 2 50 Nm (5.0 m·kg, 36 ft·lb)

Upper bracket cover bolt M8 2 19 Nm (1.9 m·kg, 13 ft·lb)

Upper bracket cover bolt M8 2 16 Nm (1.6 m·kg, 11 ft·lb)

Front brake hose guide and front brake hose guide bracket bolt

Front brake hose guide and lower bracket bolt

M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Front brake hose joint bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Bolt (lower bracket hole) M8 2 16 Nm (1.6 m·kg, 11 ft·lb)

See

NOTE.

Front fender stay bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front fender bolt M8 6 16 Nm (1.6 m·kg, 11 ft·lb)

Fuel sender bolt M5 4 4 Nm (0.4 m·kg, 2.9 ft·lb)

2-23

Page 50

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

Fuel tank bracket bolt (front side) M8 2 16 Nm (1.6 m·kg, 11 ft·lb)

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)

Fuel tank and fuel tank bracket bolt (front side)

Fuel tank and fuel tank bracket bolt (rear side)

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Meter cover bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel pump bolt M5 6 5 Nm (0.5 m·kg, 3.6 ft·lb)

Fuel return pipe holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Air filter case bracket bolt M8 3 16 Nm (1.6 m·kg, 11 ft·lb)

Canister bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

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)

For Cali-

fornia

only

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 brake caliper side)

M10 2 32 Nm (3.2 m·kg, 23 ft·lb)

Rear brake caliper bolt M10 2 27 Nm (2.7 m·kg, 19 ft·lb)

Front brake disc bolt M6 12 23 Nm (2.3 m·kg, 17 ft·lb)

Rear brake disc bolt M6 6 18 Nm (1.8 m·kg, 13 ft·lb)

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 bracket bolt

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

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)

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)

Starter motor lead bolt (starter relay side)

Positive battery lead bolt (starter relay side)

Rear fender bracket and frame bolt

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

M10 4 40 Nm (4.0 m·kg, 29 ft·lb)

2-24

Page 51

TIGHTENING TORQUES

Item

Rear fender bracket and frame bolt

Rear fender bracket and rear fender bolt

Thread

size

Q’ty Tightening torque Remarks

M10 2 40 Nm (4.0 m·kg, 29 ft·lb)

M8 4 23 Nm (2.3 m·kg, 17 ft·lb)

Passenger seat bolt M8 2 16 Nm (1.6 m·kg, 11 ft·lb)

Rider seat bracket assembly and seat lock assembly bolt

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Tool kit and battery box bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

Pressure regulator bracket bolt M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)

Cylinder-#1 ignition coil cover bolt

Cylinder-#1 ignition coil bracket bolt

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

License plate bolt M8 3 16 Nm (1.6 m·kg, 11 ft·lb)

Sidestand bolt M10 2 63 Nm (6.3 m·kg, 45 ft·lb)

Rider footrest assembly bolt (left and right)

Passenger footrest bolt (left and right)

M10 4 48 Nm (4.8 m·kg, 35 ft·lb)

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 bracket and frame bolt

Rear brake master cylinder cover bolt

Brake fluid reservoir and frame bolt

M8 2 23 Nm (2.3 m·kg, 17 ft·lb)

M8 2 16 Nm (1.6 m·kg, 11 ft·lb)

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

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 M8 2 16 Nm (1.6 m·kg, 11 ft·lb)

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) M6 1 18 Nm (1.8 m·kg, 13 ft·lb)

Shift pedal bolt (heel side) M6 1 13 Nm (1.3 m·kg, 9.4 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)

Lower front fork cover bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)

Drive pulley nut M22 1 140 Nm (14.0 m·kg, 100 ft·lb) Stake

Drive pulley cover damper plate screw

M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)

2-25

Page 52

TIGHTENING TORQUES

Item

Thread

size

Q’ty Tightening torque Remarks

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)

Throttle cable guide bolt (upper side)

Throttle cable guide bolt (lower side)

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

Rear shock absorber locknut M50 1 30 Nm (3.0 m·kg, 22 ft·lb)

Windshield holder bracket assembly bolt*

M8 4 30 Nm (3.0 m·kg, 22 ft·lb)

Windshield holder nut* M8 4 23 Nm (2.3 m·kg, 17 ft·lb)

Windshield bracket brace nut* M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)

Windshield brace nut* M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb)

Windshield lock nut* M24 1 12 Nm (1.2 m·kg, 8.7 ft·lb)

Windshield lock cover nut* M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)

Backrest upper bracket and backrest lower bracket bolt*

Backrest pad and backrest upper bracket bolt*

Backrest pad and backrest upper bracket stay bolt*

M8 4 23 Nm (2.3 m·kg, 17 ft·lb)

M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Backrest lock nut* M24 1 12 Nm (1.2 m·kg, 8.7 ft·lb)

Passenger footrest and sidebag bracket bolt (left and right)*

M10 4 47 Nm (4.7 m·kg, 34 ft·lb)

Sidebag bracket bolt* M8 4 23 Nm (2.3 m·kg, 17 ft·lb)

Sidebag bracket brace nut* M8 2 23 Nm (2.3 m·kg, 17 ft·lb)

* For XV19CTS(C), XV19CT(C) and 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.

2-26

Page 53

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20360

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20370

ENGINE

Lubrication point Lubricant

Oil seal lips

O-rings

Bearings

Cylinder head nuts and washers

Connecting rod small end and big end

Crankshaft journals

Piston surfaces

Piston pins

Connecting rod bolts

Balancer idle gear inner surface and balancer idle gear shaft

Left balancer driven gear inner surface

Right balancer

Gasket (left balancer driven gear housing)

Flange bolts (left balancer drive gear and right balancer driven gear)

Camshaft cam lobes and camshaft journals

Flange bolt (camshaft gear)

Valve push rod end balls

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Valve lifters

Rocker arms

Rocker arm shafts

Camshaft (front and rear cylinders)

Oil pump rotors (inner and outer) and oil pump housing

Oil pump driven gear shaft

Crankcase stud bolt ends

Starter clutch idle gear shaft

Starter clutch idle gear inner surface

Starter clutch gear inner surface and outer surface

Generator shaft journal

2-27

Page 54

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Lubricant

Primary driven gear inner surface

Clutch push rods and ball

Clutch boss nut and washer

Transmission gears (wheel and pinion) and collar

Drive pulley nut and washer

Shift forks and shift fork guide bars

Shift drum

Shift shaft and shift shaft oil seal

Shift fork pawl

Crankcase mating surface

Stator coil lead grommet

Crankshaft position sensor lead grommet

Yamaha bond

No.1215 (Three Bond

No.1215

)

Yamaha bond

No.1215 (Three Bond

No.1215

)

Yamaha bond

No.1215 (Three Bond

No.1215

)

2-28

Page 55

EAS20380

CHASSIS

LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Lubricant

Steering bearings and upper bearing dust cover lip

Lower bearing dust seal lip

Front wheel oil seal lips (left and right)

Rear wheel oil seal lips

Rear wheel drive hub oil seal lip

Rear wheel drive hub mating surface

Tube guide (throttle grip) inner surface and throttle cables

Brake lever pivoting point and metal-to-metal moving parts

Clutch lever pivoting point and metal-to-metal moving parts

Brake pedal shaft pivoting point

Shift pedal pivoting point

Passenger footrest pivoting point and ball

Sidestand pivoting point and metal-to-metal moving parts

Dowel pins (rear fender stay)

Pivot shaft

Swingarm pivoting point, collar flange circumference, and oil seal inner surface

Rear shock absorber bushings and O-rings

Swingarm, relay arm bearings, and oil seal lips

Connecting arm bushings and O-rings

Rear wheel axle

Clutch master cylinder push rod pin and contact surface

2-29

Page 56

LUBRICATION POINTS AND LUBRICANT TYPES

2-30

Page 57

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20390

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20400

ENGINE OIL LUBRICATION CHART

22 21

19 18

2-31

Page 58

LUBRICATION SYSTEM CHART AND DIAGRAMS

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

2-32

Page 59

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20410

LUBRICATION DIAGRAMS

A-A

B-B

E-E

D-D

2-33

Page 60

1. Oil tank

2. Dipstick

3. Oil pipe 2

4. Oil delivery pipe 1

5. Oil filter cartridge

6. Oil delivery pipe 2

7. Oil pipe 3

8. Oil pipe 4

9. Oil pipe 5

10. Oil strainer (oil tank)

11. Oil delivery pipe 3

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-34

Page 61

LUBRICATION SYSTEM CHART AND DIAGRAMS

B-B

2-35

D-D C-C

Page 62

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)

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-36

Page 63

LUBRICATION SYSTEM CHART AND DIAGRAMS

A-A

A A

2-37

Page 64

1. Oil pipe 1

2. Oil pump

3. Oil strainer (crankcase)

4. Joint pipe

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-38

Page 65

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-39

Page 66

1. Main axle

2. Drive axle

3. Oil strainer (crankcase)

4. Oil pump A. To the oil filter cartridge

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-40

Page 67

LUBRICATION SYSTEM CHART AND DIAGRAMS

B-B

2-41

Page 68

LUBRICATION SYSTEM CHART AND DIAGRAMS

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

2-42

Page 69

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-43

Page 70

1. Transfer gear oil pump

2. Middle driven shaft

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-44

Page 71

EAS20430

CABLE ROUTING

B-B C-C

2 3 4

D-D

F-F

2-45

Page 72

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. 1 0–30° 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

plastic locking tie. Face the end of the plastic

locking tie downward, and then cut off the excess

end of the tie.

CABLE ROUTING

2-46

Page 73

CABLE ROUTING

B-B

G-G F-F

D-D

E-E

2-47

Page 74

1. Main switch lead

2. Right handlebar switch lead

3. Wire harness

4. Left handlebar switch lead

5. Air temperature sensor lead

6. Front left turn signal/position light lead

7. Headlight lead

8. Front right turn signal/position light lead

9. Headlight coupler (high beam)

10. Headlight coupler (low beam)

11. Air temperature sensor

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.

CABLE ROUTING

2-48

Page 75

CABLE ROUTING

B-B

T TT

R R R R

A-A

C-C

8 9

D-D

H I

1516

H-H

G-G

J-J

F-F

2-49

Page 76

CABLE ROUTING

1. EXUP servo motor

2. Fuse box

3. Wire harness

4. Fuel outlet hose

5. Cylinder-#1 right spark plug cap

6. Cylinder-#1 right ignition coil

7. Cylinder-#2 intake air pressure sensor coupler

8. Fuel sender (fuel tank) coupler

9. Meter assembly coupler

10. Throttle cable

11. Front brake hose

12. Cylinder-#2 right spark plug cap

13. Cylinder-#1 left ignition coil

14. Clutch pipe

15. Neutral switch lead

16. Stator coil lead

17. Speed sensor lead

18. O

sensor lead

19. EXUP cable

20. Cylinder-#1 right spark plug lead

21. Cylinder-#1 left spark plug lead

22. ISC (idle speed control) unit inlet hose

23. Cylinder-#2 ISC (idle speed control) unit outlet

hose

24. Cylinder-#1 ISC (idle speed control) unit outlet

hose

25. Sub-wire harness 3 coupler

26. Cylinder-#2 right spark plug lead

27. Sub-wire harness 4 coupler

28. Cylinder-#2 left spark plug lead A. Fasten the cylinder-#1 left and right spark plug

leads, fuel outlet hose, wire harness and the fuel

tank damper with the plastic locking tie. Install the

plastic locking tie in the rear slot of the fuel tank

damper. B. Fasten the fuel outlet hose, wire harness, and fuel

tank damper with the 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. C. Fasten the cylinder-#1 left and right ignition coil

leads, engine temperature sensor lead, and throttle

position sensor lead to the guide on the engine

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.

J. Fasten the wire harness and the cylinder-#2 left

and right spark plug leads with a plastic locking tie, making sure to install the tie just past the end of the protective tube of the wire harness. Face the end of the plastic locking tie inward, and then cut off the

excess end of the tie. K. To the throttle position sensor L. To the fuel injector and engine temperature sensor M. To the neutral switch N. To the speed sensor O. Fasten the stator coil lead with the plastic locking

ties. Face the end of each plastic locking tie

outward, and then cut off the excess end of the tie. P. To the rear brake caliper Q. Install the O

sensor bracket.

R. Outside of the frame S. Position the buckle of the plastic locking tie to the

inside of the frame. Face the end of the plastic

locking tie upward, and then cut off the excess end

of the tie. T. Inside of the frame U. Position the buckle of the plastic locking tie to the

inside of the frame. V. To the wire harness W. To the cylinder-#2 right spark plug X. Right side Y. Position the sub-wire harness 3 coupler and the

sub-wire harness 4 coupler between the cylinder-

#2 right spark plug lead and the cylinder-#1 ISC

unit outlet hose. Z. Face the ends of the hose clamp outward, angled

° downward.

AA.Route the cylinder-#2 right spark plug lead under

the sub-wire harness 4. AB.Face the ends of the hose clamp downward. AC.Route the cylinder-#2 left spark plug lead under the

cylinder-#2 ISC unit outlet hose. AD.Left side AE.To the cylinder-#2 left spark plug AF. Install the clutch pipe onto the clutch release

cylinder, making sure that the pipe contacts the

projection on the cylinder. AG. To the O

AH.Align the cutout in the clutch pipe union bolt cap

with the projection on the clutch release cylinder.

sensor coupler completely onto the

sensor

2-50

Page 77

CABLE ROUTING

26 27 28 29 30 31 32

131415

D-D

LMN

15 1618

A-A

B-B

1835

G-G

C-C

2-51

Page 78

CABLE ROUTING

1. Clutch hose

2. Throttle cable (decelerator cable)

3. Throttle cable (accelerator cable)

4. Cylinder-#2 left spark plug cap

5. Cylinder-#1 left spark plug cap

6. Sub-wire harness 1

7. Rectifier/regulator

8. Crankshaft position sensor lead

9. Stator coil lead

10. Rectifier/regulator lead

11. Lean angle sensor

12. Horn 2 lead

13. Horn 2

14. Sidestand switch

15. Horn 1 lead

16. Rear brake light switch lead

17. Horn 1

18. Starter motor lead

19. Clutch pipe

20. Fuel tank breather/overflow hose

21. Rollover valve

22. Front brake hose

23. Headlight assembly

24. Front fork

25. Frame

26. Main fuse

27. Diode 1

28. Relay unit

29. Turn signal relay

30. Headlight relay

31. Starter relay

32. EXUP servo motor

33. EXUP cable

34. Speed sensor lead

35. Wire harness

36. Canister A. Route the throttle cables to the inside of the clutch

hose.

B. Pass the cylinder-#2 left spark plug lead through

the guide.

C. 30

–40 mm (1.18–1.57 in)

D. Position the buckle of the plastic locking tie to the

inside of the frame.

E. Fasten the crankshaft position sensor lead, neutral

switch lead, and sidestand switch lead with the holders.

F. Fasten the starter motor lead, speed sensor lead,

and wire harness with the holders.

G. Route sub-wire harness 1 to the inside of the

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.

K. Fasten the stator coil lead and rectifier/regulator

lead with the plastic locking tie. Face the end of the plastic locking tie outward, and then cut off the excess end of the tie.

L. Fasten the lean angle sensor lead, starter motor

lead, horn 1 lead, rear brake light switch lead, and sidestand switch lead with the holder.

M. Route the starter motor lead, horn 1 lead, rear

brake light switch lead, and sidestand switch lead to the inside of the frame boss.

N. Fasten the starter motor lead, horn 1 lead, rear

brake light switch lead, and sidestand switch lead with the plastic locking tie. Face the end of the plastic locking tie outward, and then cut off the excess end of the tie.

O. Fasten the starter motor lead, horn 1 lead, and rear

brake light switch lead with the plastic locking tie, and then face the end of the tie outward. Be sure to install the plastic locking tie behind the frame cross member and to fasten the rear brake light switch lead at the white tape.

P. Route the starter motor lead, horn 1 lead, and rear

brake light switch lead along the frame in the area shown in the illustration, making sure not to cross the leads.

Q. Align the positioning tape on the starter motor lead

with the engine mounting bolt (front lower side).

R. Pass the fuel tank breather/overflow hose through

the horn 1 bracket, making sure to position the end of the hose as shown in the illustration.

S. Fasten the starter motor lead, horn 1 lead, and rear

brake light switch lead with the plastic locking tie, and then face the end of the tie inward.

T. Fasten the horn 1 lead, rear brake light switch lead,

and starter motor 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.

U. Route the horn 1 lead to the rear of the starter

motor lead.

V. Pass the throttle cables through the cable guides

as shown in the illustration.

W. Install the lead cover, making sure not to pinch the

stator coil lead and rectifier/regulator lead.

X. Pass the plastic locking tie through the hole in the

battery box projection, and then fasten the wire harness with the tie.

Y. Fasten the stator coil lead at the white tape with the

plastic locking tie.

Z. Fasten the stator coil lead with the plastic locking

ties.

AA.Pass the plastic locking tie through the hole in the

battery box projection, and then fasten the wire harness with the tie.

AB.Route the wire harness along the side of the fuse

box/starter relay bracket. AC.For California only AD.Route the horn 1 lead to the rear of the canister.

2-52

Page 79

CABLE ROUTING

2-53

Page 80

CABLE ROUTING

1. Meter assembly coupler

2. Cylinder-#2 intake air pressure sensor coupler

3. Cylinder-#1 right spark plug cap

4. Wire harness

5. Negative battery lead

6. EXUP servo motor

7. Fuse box

8. Starter motor lead

9. Positive battery lead

10. Sub-wire harness 1

11. ECU (electronic control unit)

12. Cylinder-#1 left spark plug cap

13. Cylinder-#1 intake air pressure sensor coupler

14. Fuel sender (fuel tank) coupler

15. Neutral switch lead

16. Sidestand switch lead

17. Crankshaft position sensor lead

18. Speed sensor lead

19. Fuel hose (fuel tank to fuel hose joint)

20. Fuel return hose (fuel return pipe to sub-fuel tank)

21. Air vent hose (fuel pump to fuel hose joint)

22. Fuel outlet hose

23. Frame

24. Oil tank

25. Sub-fuel tank

26. Battery

27. Main fuse

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

then cut off the excess end of the tie. 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

excess end of the tie. 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.

L. Fasten the air filter case damper with the plastic

locking tie so that the rubber part of the damper contacts the frame. Be sure to pass the plastic locking tie between the air filter case damper and the frame.

M. Route the crankshaft position sensor lead,

sidestand switch lead, neutral switch lead, starter motor lead, and speed sensor lead under the fuel

outlet hose. N. Inside of frame O. Outside of frame P. View with tray removed Q. Route the negative battery lead under the starter

motor lead and battery positive lead. R. Route the positive battery lead (main fuse to starter

relay) over the tray. S. Route the negative battery lead towards the front of

the vehicle. T. Route the positive battery lead (battery to starter

relay) under the tray. U. View with tray installed V. To the tail/brake light W. View with ECU removed X. Wrap the protective covering around the couplers

(crankshaft position sensor coupler, auxiliary DC

jack coupler, neutral switch coupler, sub-wire

harness 1 coupler, speed sensor coupler, and

sidestand switch coupler) and the wire harness. Y. When installing the ECU, be sure not to pinch the

leads in the areas shown in the illustration with

oblique lines.

2-54

Page 81

CABLE ROUTING

C-C

2-55

Page 82

CABLE ROUTING

1. Fuel tank breather hose

2. Fuel sender (fuel tank)

3. Fuel tank

4. Fuel hose (fuel tank to fuel hose joint)

5. Fuel return hose (fuel return pipe to sub-fuel tank)

6. Air vent hose (fuel hose joint to fuel tank)

7. Fuel hose joint

8. Fuel outlet hose

9. Fuel pump

10. Sub-fuel tank

11. Fuel hose (fuel hose joint to fuel pump)

12. Fuel return pipe

13. Fuel return hose (pressure regulator to fuel return pipe)

14. Pressure regulator

15. Rollover valve 1

16. Rollover valve 2

17. Cylinder-#2 left spark plug lead

18. Rollover valve hose 1

19. Rollover valve hose 2

20. Starter motor lead

21. Fuel tank breather/overflow hose

22. Rollover valve hose 4

23. Rollover valve hose 3

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

sure that the projections on the clamp are positioned as shown in the illustration.

Q. Install the fuel hose (fuel tank to fuel hose joint)

with its white paint mark facing downward. R. To the pressure regulator S. Install the air vent hose (fuel hose joint to fuel tank)

with its white paint mark facing downward. T. For California only U. To the fuel tank V. To the intake manifold assembly W. Fasten the canister purge hose and fuel tank

breather/overflow hose with the holder, making sure

to align the paint mark on the breather/overflow

hose with the holder. X. Fasten the canister purge hose and throttle cable

guide with the holder.

2-56

Page 83

CABLE ROUTING

C-C

2-57

Page 84

1. Cylinder-#1 intake air pressure sensor

2. Cylinder-#1 intake air pressure sensor hose

3. Air filter case breather hose 1

4. Fuel hose (intake manifold assembly to pressure regulator)

5. Pressure regulator

6. Air filter case breather hose 2

7. Canister purge hose (for California only)

8. ISC (idle speed control) unit inlet hose

9. Canister (for California only)

10. Fuel tank breather/overflow hose (for California only)

11. Cylinder-#2 ISC (idle speed control) unit outlet hose

12. ISC (idle speed control) unit

13. Cylinder-#1 ISC (idle speed control) unit outlet hose

14. Cylinder-#2 intake air pressure sensor

15. Cylinder-#1 intake air pressure sensor hose

16. Fuel outlet hose

17. Cylinder head breather hose

18. Hose joint cover

19. Throttle position sensor

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

° 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

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 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.

CABLE ROUTING

2-58

Page 85

CABLE ROUTING

2 3

2-59

Page 86

1. Cylinder-#1 intake air pressure sensor

2. Cylinder-#2 intake air pressure sensor hose

3. Cylinder-#2 intake air pressure sensor

4. ISC (idle speed control) unit coupler

5. ISC (idle speed control) unit

6. Rollover valve 1

7. Rollover valve 2

8. ISC (idle speed control) unit inlet hose

9. Cylinder-#1 ISC (idle speed control) unit outlet hose

10. Cylinder-#2 ISC (idle speed control) unit outlet hose

11. Hose joint

12. Air filter case breather hose 2

13. Throttle position sensor

14. Throttle body assembly

15. Cylinder-#1 intake air pressure sensor hose

16. Cylinder head breather hose

17. Cylinder-#2 left ignition coil

18. Cylinder-#2 right ignition coil

19. Sub-wire harness 4

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

outlet hose onto the ISC unit pipe, making sure to align the green paint mark on the hose with the green paint mark on the pipe.

CABLE ROUTING

2-60

Page 87

CABLE ROUTING

2-61

Page 88

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

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 ................................................... 3-17

CHECKING THE CANISTER (for California only)................................... 3-18

ADJUSTING THE EXUP CABLES.......................................................... 3-18

CHASSIS....................................................................................................... 3-20

ADJUSTING THE REAR DISC BRAKE.................................................. 3-20

CHECKING THE BRAKE FLUID LEVEL ................................................ 3-20

CHECKING THE FRONT BRAKE PADS................................................ 3-21

CHECKING THE REAR BRAKE PADS .................................................. 3-21

CHECKING THE FRONT BRAKE HOSES............................................. 3-21

CHECKING THE REAR BRAKE HOSES ............................................... 3-22

ADJUSTING THE REAR BRAKE LIGHT SWITCH................................. 3-22

BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-22

ADJUSTING THE SHIFT PEDAL............................................................ 3-23

ADJUSTING THE DRIVE BELT SLACK................................................. 3-24

CHECKING AND ADJUSTING THE STEERING HEAD......................... 3-25

CHECKING THE FRONT FORK............................................................. 3-26

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-27

CHECKING THE TIRES ......................................................................... 3-27

CHECKING THE WHEELS..................................................................... 3-29

CHECKING AND LUBRICATING THE CABLES .................................... 3-29

LUBRICATING THE LEVERS................................................................. 3-30

LUBRICATING THE PEDAL ................................................................... 3-30

LUBRICATING THE SIDESTAND .......................................................... 3-30

LUBRICATING THE REAR SUSPENSION ............................................ 3-30

Page 89

ELECTRICAL SYSTEM ................................................................................ 3-31

CHECKING AND CHARGING THE BATTERY....................................... 3-31

CHECKING THE FUSES ........................................................................ 3-31

REPLACING THE HEADLIGHT BULBS................................................. 3-31

ADJUSTING THE HEADLIGHT BEAMS................................................. 3-32

Page 90

Page 91

PERIODIC MAINTENANCE

EAS20450

PERIODIC MAINTENANCE

EAS20460

INTRODUCTION

This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer 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

No. ITEM ROUTINE

1 * Fuel line

2 * Spark plugs

3 * Valve clearance

Crankcase

4 *

breather system

5 * Fuel injection • Adjust synchronization. √√√√√

6 * Exhaust system

Evaporative emission control sys-

7 *

tem (For California only)

• Check fuel hoses for cracks or damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

• Replace every 8000 mi

(13000 km) or 12 months.

• Check and adjust valve clearance when engine is cold.

• Adjust if necessary.

• Check breather hose for

cracks or damage.

• Replace if necessary.

• Check for leakage.

• Tighten if necessary.

• Replace gasket(s) if neces-

sary.

• Check control system for damage.

• Replace if necessary.

600 mi

(1000 km)

1 month

4000 mi

(7000 km)

6 months

√√√√√

√ Replace. √ Replace. √

√√√√√

8000 mi

(13000

km)

12 months

Every 16000 mi (25000 km)

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the

service.

12000 mi

(19000

km)

18 months

16000 mi

(25000

km)

24 months

√√

20000 mi

(31000

km)

30 months

EAU32183

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

1 * Air filter element

2 * Clutch

3 * Front brake

4 * Rear brake

5 * Brake hoses

• Check condition and damage.

• Replace if necessary.

• Check operation and fluid

leakage.

• Correct if necessary.

• Check operation, fluid level,

and for fluid leakage.

• Replace brake pads if necessary.

• Check operation, fluid level, and for fluid leakage.

• Replace brake pads if necessary.

• Check for cracks or damage. √√√√√

• Replace. Every 4 years

600 mi

(1000 km)

1 month

√√√√√√

4000 mi

(7000 km)

6 months

3-1

8000 mi

(13000

√√√√√

km)

12 months

12000 mi

(19000

km)

18 months

16000 mi

(25000

km)

24 months

20000 mi

(31000

km)

30 months

Page 92

PERIODIC MAINTENANCE

INITIAL ODOMETER READINGS

No. ITEM ROUTINE

6 * Wheels

7 * Tires

8 * Wheel bearings

Swingarm pivot

9 *

bearings

10 * Drive belt

11 * Steering bearings

12 * Chassis fasteners

Brake and clutch

lever pivot shafts

Brake and shift

pedal pivot shafts

15 Sidestand pivot

16 * Sidestand switch

17 * Front fork

Shock absorber

18 *

assembly

Rear suspension

19 *

link pivots

20 Engine oil

Engine oil filter

21 *

cartridge

22 * Transfer case oil

Front and rear

23 *

brake switches

24 * Control cables

Throttle grip

25 *

housing and cable

Lights, signals

26 *

and switches

• Check runout and for damage.

• Replace if necessary.

• Check tread depth and for

damage.

• Replace if necessary.

• Check air pressure.

• Correct if necessary.

• Check bearings for smooth

operation.

• Replace if necessary.

• Check bearing assemblies for

looseness.

• Check belt tension.

• Adjust if necessary.

• Check bearing assemblies for

looseness.

• Moderately repack with lithium-soap-based grease every 16000 mi (25000 km) or 24 months.

• Check all chassis fitting and fasteners.

• Correct if necessary.

• Apply lithium-soap-based

grease (all-purpose grease) lightly.

• Apply lithium-soap-based grease (all-purpose grease) lightly.

• Check operation.

• Apply lithium-soap-based

grease (all-purpose grease) lightly.

• Check operation and replace if necessary.

• Check operation and for oil leakage.

• Replace if necessary.

• Check operation and for oil

leakage.

• Replace if necessary.

• Apply lithium-soap-based

grease lightly.

• Change (warm engine before draining).

• Replace. √√√

• Check for leakage.

• Change at initial 600 mi (1000

km) or 1 month, and thereafter every 16000 mi (25000 km) or 24 months.

• Check operation. √√√√√√

• Apply Yamaha chain and ca-

ble lube or engine oil SAE 10W-30 thoroughly.

• Check operation and free play.

• Adjust the throttle cable free play if necessary.

• Lubricate the throttle grip housing and cable.

• Check operation.

• Adjust headlight beam.

600 mi

(1000 km)

1 month

√ Every 2500 mi (4000 km)

√√√√Repack. √

√√√√√√

Change. √ Change.

√√√√√√

4000 mi

(7000 km)

6 months

√√√√√

8000 mi

(13000

km)

12 months

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the

service.

12000 mi

(19000

km)

18 months

16000 mi

(25000

km)

24 months

√

20000 mi

(31000

km)

30 months

3-2

Page 93

PERIODIC MAINTENANCE

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

Page 94

ENGINE

EAS20470

ENGINE

EAS20530

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the valves.

NOTE:

• The valve clearance is automatically adjusted by the hydraulic valve lifter. However, there are times when the valve clearance needs to be adjusted manually. If this is the case, adjust the clearance of the two maladjusted or worn valves using the adjusting screw on the rocker 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.

• Fuel tank Refer to “FUEL TANK” on page 6-1.

• Air filter case Refer to “GENERAL CHASSIS” on page 4-1.

• Muffler

• Exhaust pipes

Refer to “ENGINE REMOVAL” on page 5-1.

2. Disconnect:

• Spark plug caps

3. Remove:

• Spark plugs

4. Remove:

• Shift pedal assembly “1”

If clearance is on the adjusting screw “2” side, tighten the adjusting screw and bring the valve clearance “b” within specification.

• Valve clearance adjustment should be made on a cold engine, at room temperature.

• When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

5. Remove:

• Damper cover “1”

• Damper “2”

• Timing mark accessing screw “3”

• Crankshaft end screw “4”

6. Remove:

• Camshaft sprocket cover “1”

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

Page 95

ENGINE

8. Remove:

• Fuel tank damper “1”

• Cylinder head breather hose “2”

9. Disconnect:

• Oil tank breather hose “3”

• Fuel outlet hose “4”

11.Measure:

• Valve clearance

Out of specification → Adjust.

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)

▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

Piston #1 TDC (rear cylinder)

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 place. Loosen the bolts, and then remove the cylinder head cover from the right side of the vehicle, making sure that the bolts do not scratch the rocker arms or other engine parts.

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.

c. Check the camshaft drive gear mark “c” posi-

tion and camshaft driven gear mark “d” position as shown. If the marks are not aligned, turn the crankshaft counterclockwise 360 degrees and recheck step (b).

3-5

Page 96

d. Measure the valve clearance with a thickness

gauge.

Thickness gauge

90890-03180

Feeler gauge set

YU-26900-9

▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲

▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼

Piston #2 TDC (front cylinder)

a. Turn the crankshaft counterclockwise from

the piston #1 TDC by 408 degrees.

b. When piston #2 is at TDC on the compres-

sion stroke, align the TDC mark “e” on the crankshaft position sensor rotor with the pointer “b” on the clutch cover.

ENGINE

Thickness gauge

90890-03180

▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

12.Adjust:

• Valve clearance

▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Loosen the locknut “1”.

b. Insert a thickness gauge “2” between the end

of the adjusting screw and the valve tip.

Feeler gauge set

YU-26900-9

Thickness gauge

90890-03180

Feeler gauge set

YU-26900-9

c. Check the camshaft drive gear mark “c” posi-

tion and camshaft driven gear mark “d” position as shown.

d. Measure the valve clearance with a thickness

gauge.

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 Valve adjustment wrench 3 mm & 4 mm

YM-08035-A

Direction “a”

Direction “b”

Adjusting

screw side

Valve clearance is increased.

Valve clearance is decreased.

Slip side

Valve clearance is decreased.

Valve clearance is increased.

3-6

Page 97

ENGINE

• Cylinder-#1 ignition coil cover Refer to “ENGINE REMOVAL” on page 5-1.

• Fuel tank Refer to “FUEL TANK” on page 6-1.

3. Remove:

• Cylinder-#1 intake air pressure sensor bracket “1”

• Cylinder-#2 intake air pressure sensor bracket “2”

d. Hold the adjusting screw to prevent it from

moving and tighten the locknut to specification.

Locknut (rocker arm adjusting

screw)

20 Nm (2.0 m·kg, 14 ft·lb)

Tappet adjusting tool (4 mm)

90890-04133 Valve adjustment wrench 3 mm & 4 mm

YM-08035-A

e. Measure the valve clearance again. f. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲

13.Install:

• All removed parts Refer to “CAMSHAFTS” on page 5-14.

NOTE:

For installation, reverse the removal procedure.

EAS20570

SYNCHRONIZING THE THROTTLE BODIES

NOTE:

Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked.

1. Stand the vehicle on a level surface.

NOTE:

Place the vehicle on a suitable stand.

2. Remove:

• Rider seat

• Rider seat bracket assembly Refer to “GENERAL CHASSIS” on page 4-1.

4. Disconnect:

• Cylinder-#1 intake air pressure sensor hose “1”

• Cylinder-#2 intake air pressure sensor hose “2”

5. Install:

• Hose “1” (Parts No.: 5JW-24311-00)

• 3-way joint “2” (Parts No.: 90413-05014)

• Vacuum gauge hose for #1 “3”

• Vacuum gauge hose for #2 “4”

• Cylinder-#1 intake air pressure sensor hose “5”

• Cylinder-#2 intake air pressure sensor hose “6”

• Vacuum gauge

• Tachometer

Vacuum gauge

90890-03094

Carburetor synchronizer

YU-44456

3-7

Page 98

6. Install:

• Fuel tank Refer to “FUEL TANK” on page 6-1.

7. Adjust:

• Throttle body synchronization

▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼

a. Start the engine and let it warm up for several

minutes, and then let it run at specified engine idling speed.

Engine idling speed

850–950 r/min

b. With throttle body #1 as standard, adjust

throttle body #2 using the air screw “1” (for throttle body #2).

ENGINE

NOTE:

The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg).

▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

8. Stop the engine and remove the measuring equipment.

9. Adjust:

• Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-8.

Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)

10.Install:

• Fuel tank Refer to “FUEL TANK” on page 6-1.

• Cylinder-#1 ignition coil cover Refer to “ENGINE REMOVAL” on page 5-1.

• Rider seat bracket assembly

• Rider seat

Refer to “GENERAL CHASSIS” on page 4-1.

EAS20630

ADJUSTING THE THROTTLE CABLE FREE PLAY

NOTE:

Prior to adjusting the throttle cable free play, the engine idling speed and throttle body synchronization should be adjusted properly.

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 throttle body.

ECA14900

CAUTION:

Do not use the throttle valve adjusting screws to adjust the throttle body synchronization.

Intake vacuum

31.3–35.3 kPa (9.3–10.4 inHg) (235–265 mmHg)

1. Check:

• Throttle cable free play “a”

Out of specification → Adjust.

Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)

2. Adjust:

• Throttle cable free play

3-8

Page 99

ENGINE

▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼▼▼▼

a. Loosen the locknut “1”. b. Turn the adjusting nut “2” in direction “a” or “b”

until the specified throttle cable free play is obtained.

Direction “a”

Throttle cable free play is increased.

Direction “b”

Throttle cable free play is decreased.

c. Tighten the locknut “1”.

EWA12910

WARNING

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.

4. Check:

• Spark plug type

Incorrect → Change.

Manufacturer/model

NGK/DPR8EA-9

Manufacturer/model

DENSO/X24EPR-U9

5. Check:

• Electrode “1”

Damage/wear → Replace the spark plug.

• 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)

7. Measure:

• Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap.

Spark plug gap

0.8–0.9 mm (0.031–0.035 in)

▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲▲▲▲

EAS20680

CHECKING THE SPARK PLUGS

The following procedure applies to all of the spark plugs.

1. Remove:

• Rider seat

• Rider seat bracket assembly Refer to “GENERAL CHASSIS” on page 4-1.

• Fuel tank Refer to “FUEL TANK” on page 6-1.

• Air filter case

Refer to “GENERAL CHASSIS” on page 4-1.

2. Disconnect:

• Spark plug cap

3. Remove:

• Spark plug

ECA13320

CAUTION:

Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders.

8. Install:

• Spark plug

Spark plug

NOTE:

18 Nm (1.8 m·kg, 13 ft·lb)

Before installing the spark plug, clean the spark plug and gasket surface.

9. Connect:

• Spark plug cap

3-9

Page 100

10.Install:

• Air filter case Refer to “GENERAL CHASSIS” on page 4-1.

• Fuel tank Refer to “FUEL TANK” on page 6-1.

• Rider seat bracket assembly

• Rider seat

Refer to “GENERAL CHASSIS” on page 4-1.

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.

ENGINE

5. Check:

• Ignition timing

▼▼▼▼ ▼ ▼▼▼▼▼▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Start the engine, warm it up for several min-

utes, and then let it run at the specified engine idling speed.

1. Stand the vehicle on a level surface.

2. Remove:

• Shift pedal assembly “1”

3. Remove:

• Damper cover “1”

• Damper “2”

• Timing mark accessing screw “3”

Engine idling speed

850–950 r/min

b. Check that pointer “a” on the clutch cover is

within the firing range “b” on the crankshaft position sensor rotor. Incorrect firing range → Check the ignition system.

NOTE:

The ignition timing is not adjustable.

▲▲▲▲ ▲ ▲▲▲▲▲▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

6. Install:

• Timing mark accessing screw

• Damper

• Damper cover

4. Connect:

• Timing light “1”

• Tachometer

Timing light

90890-03141

Inductive clamp timing light

YU-03141

3-10

Damper cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

7. Install:

• Shift pedal assembly “1”

Shift pedal bolt

18 Nm (1.8 m·kg, 13 ft·lb)

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

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

GENERAL INFORMATION

IDENTIFICATION

FEATURES

IMPORTANT INFORMATION

CHECKING THE CONNECTIONS

SPECIAL TOOLS

SPECIFICATIONS

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

TIGHTENING TORQUES

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION SYSTEM CHART AND DIAGRAMS

CABLE ROUTING

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

ENGINE