2013 Yamaha Raider S Stratoliner S Roadliner S Service Manual

2013
SERVICE MANUAL
XV19SD(C)
XV19CTSD(C)
XV19CSD(C)
XV19CD(C)
LIT-11616-26-33 1D7-28197-14
EAS20050
XV19SD(C)/XV19CTSD(C)/
XV19CSD(C)/XV19CD(C)
SERVICE MANUAL
©2012 by Yamaha Motor Corporation, U.S.A.
First edition, July 2012
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-26-33
EAS20071
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20081
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential person-
al injury hazards. Obey all safety messages that follow this symbol to
avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could

WARNING result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EAS20090
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
7
4
5
2
6
EAS20100
8. Electrical data
SYMBOLS 9. Engine oil
The following symbols are used in this manual 10. Gear oil
for easier understanding. 11. Molybdenum-disulfide oil
TIP 12. Brake fluid
The following symbols are not relevant to every 13. Wheel-bearing grease
vehicle. 14. Lithium-soap-based grease
15. Molybdenum-disulfide grease
16. Silicone grease
1 2 3 17. Apply locking agent (LOCTITE®).
18. Replace the part with a new one.
4 5 6
T.
R.
7 8
9 10
E G
11 12
M BF
13 14
B LS
15 16
M S
17 18
LT New
1. Serviceable with engine mounted

2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening torque
6. Wear limit, clearance
7. Engine speed
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
FUEL SYSTEM 6
ELECTRICAL SYSTEM 7
TROUBLESHOOTING 8
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
FEATURES...................................................................................................... 1-2
1
OUTLINE OF THE FI SYSTEM.................................................................1-2
FI SYSTEM................................................................................................1-3
INSTRUMENT FUNCTIONS (for XV19S(C)/ XV19CTS(C)) ..................... 1-4
INSTRUMENT FUNCTIONS (for XV19CS(C)/ XV19C(C)) .......................1-7
IMPORTANT INFORMATION ....................................................................... 1-10

PREPARATION FOR REMOVAL AND DISASSEMBLY......................... 1-10
REPLACEMENT PARTS.........................................................................1-10
GASKETS, OIL SEALS AND O-RINGS .................................................. 1-10
LOCK WASHERS/PLATES AND COTTER PINS ................................... 1-10
BEARINGS AND OIL SEALS .................................................................. 1-11
CIRCLIPS ................................................................................................1-11
CHECKING THE CONNECTIONS ................................................................1-12
SPECIAL TOOLS .......................................................................................... 1-13

IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

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

The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum
air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In
the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion
chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the
respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con-
ditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the
fuel through the use of jets have been provided with various auxiliary devices, so that an optimum air-
fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en-
gine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases increase,
it becomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom-
modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place
of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by
the engine at all times by using a microprocessor that regulates the fuel injection volume according to
the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine response,
better fuel economy, and reduced exhaust emissions.
1 2 3 4 56 7 8 9 10 11 12 13
22 21 17 20 19 18 17 16 15 14
1. Air temperature sensor 12. Relay unit (fuel pump relay)
2. ISC (idle speed control) unit 13. EXUP servo motor
3. Engine temperature sensor 14. Speed sensor
4. Cylinder-#2 left and right ignition coils (for 15. O2 sensor
XV19CS(C)/ XV19C(C)) 16. Lean angle sensor
5. Cylinder-#1 right ignition coil (for XV19S(C)/ 17. Spark plug
XV19CTS(C))
18. Injector #1
6. Throttle position sensor
19. Crankshaft position sensor
7. Cylinder-#1 left and right ignition coils (for
XV19CS(C)/ XV19C(C)) 20. Injector #2
8. Cylinder-#1 left ignition coil (for XV19S(C)/ 21. Cylinder-#2 right ignition coil (for XV19S(C)/
XV19CTS(C)) XV19CTS(C))
9. Intake air pressure sensor 22. Cylinder-#2 left ignition coil (for XV19S(C)/
XV19CTS(C))
10. Fuel pump
11. ECU (engine control unit)
1-2
FEATURES
ET1D71018
FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at 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 dura-
tion), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, crankshaft position sensor, intake air pressure sensor, air temperature sensor,
engine temperature sensor, speed sensor and O2 sensor enable the ECU to determine the injection
duration. The injection timing is determined through the signals from the crankshaft position sensor. As
a result, the volume of fuel that is required by the engine can be supplied at all times in accordance with
the driving conditions.
Illustration is for reference only.
6
7
1 8
2 C
A 5
3
#2 #1
4 9
15 10
B
14
13 11
12
1. Pressure regulator 13. Intake air pressure sensor

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

XV19CTS(C))
Multi-function meter unit
4 2
1. Speedometer
2. Fuel gauge
3. Odometer/tripmeter/fuel reserve
tripmeter/clock
4. Tachometer
EWA1D7K001 1. “SELECT” switch
WARNING 2. “RESET” switch
Be sure to stop the vehicle before making
any setting changes to the multi-function Speedometer
meter unit. Changing settings while riding
can distract the operator and increase the 1
risk of an accident.
The multi-function meter unit is equipped with
the following:
• a speedometer
• a tachometer
• a fuel gauge
• an odometer
• two tripmeters (which show the distance trav-
1. Speedometer
eled since they were last set to zero)
• a fuel reserve tripmeter (which shows the dis- The speedometer shows the riding speed.
tance traveled on the fuel reserve) When the key is turned to “ON”, the speedome-
• a clock ter needle will sweep once across the speed
• a self-diagnosis device range and then return to zero in order to test the
• a brightness control mode electrical circuit.
TIP
• Be sure to turn the key to “ON” before using the
“SELECT” and “RESET” switches, except for
setting the brightness control mode.
• To switch the odometer, the tripmeters and the
fuel reserve tripmeter displays between kilo-
meters and miles, press the “SELECT” switch
for at least two seconds. (for USA and Califor-
nia only)
1-4
FEATURES
Tachometer Odometer, tripmeter, fuel reserve tripmeter,

and clock
2
1
1. Tachometer
2. Tachometer red zone 1. Odometer/tripmeter/fuel reserve
tripmeter/clock
The electric tachometer allows the rider to mon-
itor the engine speed and keep it within the ideal Push the “SELECT” switch to switch the display
power range. between the odometer mode “ODO”, the tripme-
When the key is turned to “ON”, the tachometer ter modes “TRIP 1” and “TRIP 2” and the clock
needle will sweep once across the r/min range mode in the following order:
and then return to zero r/min in order to test the ODO → TRIP 1 → TRIP 2 → Clock → ODO
electrical circuit. If the fuel level warning light comes on, the
EC1D71017 odometer display will automatically change to
NOTICE the fuel reserve tripmeter mode “F-TRIP” and
Do not operate the engine in the tachometer start counting the distance traveled from that
red zone. point. In that case, push the “SELECT” switch to
Red zone: 5000 r/min and above switch the display between the various tripme-
ter, odometer, and clock modes in the following
order:
Fuel gauge
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
1 itself automatically, and the display will return to
the prior mode after refueling and traveling 5 km
(3 mi).
To set the clock

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. 1. Clock
TIP
The fuel gauge does not indicate the correct fuel
level for the first 5 km/h (3 mi/h) after refueling.
1-5
FEATURES
1. Push the “SELECT” switch to change the dis- 2. LCD

play to the clock mode. 3. Speedometer needle
2. Push the “SELECT” and “RESET” switches 4. Tachometer needle
together for at least two seconds. 5. Fuel gauge needle
3. When the hour digits start flashing, push the
The brightness can be adjusted for the following:
“RESET” switch to set the hours.
• the multi-function meter unit panel (item num-
4. Push the “SELECT” switch, and the minute
ber “1”)
digits will start flashing.
• the LCD (item number “2”)
5. Push the “RESET” switch to set the minutes.
• the speedometer, tachometer, and the fuel
6. Push the “SELECT” switch and then release
gauge needles (item number “3”)
it to start the clock.
Select the brightness control mode as follows.
1. Turn the key to “OFF”.
Self-diagnosis device
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
1
1. Fault code display 2

This model is equipped with a self-diagnosis de- 3
vice for various electrical circuits.
If a problem is detected in any of those circuits, 1. Multi-function meter unit panel
the engine trouble warning light will come on or 2. Item number
flash, and the odometer/tripmeter/clock display 3. Brightness level
will indicate an fault code.
If the odometer/tripmeter/clock display indicates 4. Adjust the multi-function meter unit panel
any fault codes, note the code number, and then brightness level by pushing the “RESET”
check the vehicle. Refer to “FUEL INJECTION switch.
SYSTEM” on page 7-27. 5. Push the “SELECT” switch to select the LCD.
ECA1D7K003 Item number “2” is displayed.
NOTICE Adjust the LCD brightness level by pushing
If the display indicates an fault code, the ve- the “RESET” switch.
hicle should be checked as soon as possible
in order to avoid engine damage.
Brightness control mode
1 1 2
3 3
4
5 1. LCD
2 2. Item number
3. Brightness level
1. Multi-function meter unit panel
1-6
FEATURES
6. Push the “SELECT” switch to select the The multi-function meter unit is equipped with
speedometer, tachometer, and the fuel the following:
gauge needles. • a speedometer
Item number “3” is displayed. • a fuel gauge
Adjust the brightness level of the speedome- • an odometer
ter, tachometer, and the fuel gauge needles • two tripmeters (which show the distance trav-
by pushing the “RESET” switch. eled since they were last set to zero)
• a fuel reserve tripmeter (which shows the dis-
tance traveled on the fuel reserve)
1 • a clock
• a self-diagnosis device
2 • a brightness control mode
3 TIP
4 Be sure to turn the key to “ON” before using the
“SELECT” and reset switches, except for setting
5
the brightness control mode.
1. Speedometer needle
2. Tachometer needle
3. Fuel gauge needle
4. Item number
5. Brightness level
7. Push the “SELECT” switch.
The odometer/tripmeter/clock display will re-
turn to the prior mode.
EAS1D77010
INSTRUMENT FUNCTIONS (for XV19CS(C)/ 1. “SELECT” switch

XV19C(C))
Multi-function meter unit 5080

60 100 70 120 80 90
140
100
160
40
60
110
30 180
40
120
20 200
20 130
10 220
0
0
km/h 140
MPH
1. Reset switch
1. Speedometer Speedometer
tripmeter/clock
3. Fuel gauge
EWA1D7K001
WARNING
Be sure to stop the vehicle before making
any setting changes to the multi-function
meter unit. Changing settings while riding
can distract the operator and increase the
risk of an accident.
1. Speedometer
1-7
FEATURES
When the key is turned to “ON”, the speedome- point. In that case, push the “SELECT” switch to
ter needle will sweep once across the speed change the display between the various tripme-
range and then return to zero in order to test the ter and odometer modes in the following order:
electrical circuit. F-TRIP → TRIP A → TRIP B → ODO → F-TRIP
To reset a tripmeter, select it by pushing the “SE-
Fuel gauge LECT” switch, and then push the reset switch for
at least one second. If you do not reset the fuel
reserve tripmeter manually, it will reset itself au-
tomatically, and the display will return to the prior
mode after refueling and traveling 5 km (3 mi).
To set the clock
1 1
1. Fuel gauge
The fuel gauge indicates the amount of fuel in
the fuel tank. The needle moves towards “E”
(Empty) as the fuel level decreases. When the
needle reaches “E”, approximately 3.2 L (0.85
US gal) (0.70 Imp.gal) remain in the fuel tank. If
1. Clock
this occurs, refuel as soon as possible.
When the key is turned to “ON”, the fuel gauge 1. Push the “SELECT” and reset switches to-
needle will sweep once across the fuel level gether for at least three seconds.
range and then return to the current amount in 2. When the hour digits start flashing, push the
order to test the electrical circuit. reset switch to set the hours.
3. Push the “SELECT” switch, and the minute
Odometer, tripmeters, fuel reserve tripmeter digits will start flashing.
and clock 4. Push the reset switch to set the minutes.
5. Push the “SELECT” switch and then release
it to start the clock.
1 Self-diagnosis devices
2
1
tripmeter/clock
Push the “SELECT” switch to change the display
between the odometer mode “ODO”, the tripme-
ter modes “TRIP A” and “TRIP B” in the following 1. Fault code display
order: 2. Engine trouble warning light “ ”
ODO → TRIP A → TRIP B → ODO This model is equipped with a self-diagnosis de-
If the fuel level warning light comes on, the vice for various electrical circuits.
odometer display will automatically change to If a problem is detected in any of those circuits,
the fuel reserve tripmeter mode “F-TRIP” and the engine trouble warning light will come on and
start counting the distance traveled from that the odometer/tripmeter/clock display will indi-
cate an fault code.
1-8
FEATURES
If the odometer/tripmeter/clock display indicates

any fault codes, note the code number, and then
check the vehicle. Refer to “FUEL INJECTION
SYSTEM” on page 7-27.
ECA1D7K004
NOTICE
If the display indicates an fault code, the ve-
hicle should be checked as soon as possible
in order to avoid engine damage.
Brightness control mode

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

1. Turn the key to “OFF”.
2. Push and hold the “SELECT” switch.
3. Turn the key to “ON”, and then release the
“SELECT” switch after five seconds.

2. Brightness level
4. Adjust the multi-function meter unit panel
brightness level by pushing the reset switch.
5. Push the “SELECT” switch.
The odometer/tripmeter/clock display will re-
turn to the prior mode.
1-9
IMPORTANT INFORMATION
EAS20180
EAS20190
PREPARATION FOR REMOVAL AND

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

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-13.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER

PINS
4. During disassembly, clean all of the parts and After removal, replace all lock washers/plates
place them in trays in the order of disassem- “1” and cotter pins. After the bolt or nut has been
bly. This will speed up assembly and allow for tightened to specification, bend the lock tabs
the correct installation of all parts. along a flat of the bolt or nut.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-10
EAS20230
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropri-
ate.
ECA13300
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-11
CHECKING THE CONNECTIONS
EAS20250
CHECKING THE CONNECTIONS Pocket tester

Check the leads, couplers, and connectors for 90890-03112
stains, rust, moisture, etc. Analog pocket tester
1. Disconnect: YU-03112-C
• Lead
• Coupler TIP
• Connector • If there is no continuity, clean the terminals.
2. Check: • When checking the wire harness, perform
• Lead steps (1) to (3).
• Coupler • As a quick remedy, use a contact revitalizer
• Connector available at most part stores.
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection → Connect properly.
TIP
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
• Lead
• Coupler
• Connector
TIP
Make sure all connections are tight.
5. Check:
• Continuity
(with the pocket tester)
1-12
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.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-12, 5-85,
90890-03112 7-75, 7-76,
Analog pocket tester 7-77, 7-81,
YU-03112-C 7-82, 7-83,
7-84, 7-85,
7-86, 7-87,
7-88, 7-89,
7-90, 7-92
Thickness gauge 3-6, 5-65
90890-03180
Feeler gauge set
YU-26900-9
Tappet adjusting tool (4 mm) 3-6, 3-7

90890-04133
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Vacuum gauge 3-7
90890-03094
Vacuummate
YU-44456
YU-44456
1-13
SPECIAL TOOLS
Reference
pages
Timing light 3-10
90890-03141
YU-03141
Oil filter wrench 3-12

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

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

90890-01403
Exhaust flange nut wrench
YU-A9472
Damper rod holder 4-71, 4-73

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

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

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

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

90890-04019
YM-04019
1-14
SPECIAL TOOLS
Reference
pages
Valve guide remover (ø6) 5-43
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A
Valve guide installer (ø6) 5-43

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

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

90890-01304
Piston pin puller
YU-01304
YU-01304
Universal clutch holder 5-64, 5-70

90890-04086
YM-91042
Sheave holder 5-64, 5-69,

90890-01701 5-70, 5-80,
Primary clutch holder 5-81
YS-01880-A
1-15
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 5-71, 5-81,
90890-85505 5-99
(Three Bond No.1215®)
Rotor puller 5-80

90890-01080
Stator rotor puller
YM-01080-A
Vacuum/pressure pump gauge set 6-15

90890-06756
Mityvac brake bleeding tool
YS-42423
Pressure gauge 6-15

90890-03153
YU-03153
Fuel pressure adapter 6-15

90890-03176
YM-03176
Digital circuit tester 6-15

90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Ignition checker 7-84

90890-06754
Oppama pet-4000 spark checker
YM-34487
1-16
SPECIAL TOOLS
1-17
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-3
CHASSIS SPECIFICATIONS ........................................................................2-11
ELECTRICAL SPECIFICATIONS .................................................................2-16
TIGHTENING TORQUES .............................................................................. 2-19

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-19
ENGINE TIGHTENING TORQUES......................................................... 2-20
CHASSIS TIGHTENING TORQUES.......................................................2-25
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-32

ENGINE................................................................................................... 2-32
CHASSIS.................................................................................................2-34
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-35

ENGINE OIL LUBRICATION CHART .....................................................2-35
LUBRICATION DIAGRAMS .................................................................... 2-37
CABLE ROUTING (for XV19S(C)/ XV19CTS(C)).........................................2-49
CABLE ROUTING (for XV19CS(C)/ XV19C(C))...........................................2-67

GENERAL SPECIFICATIONS
EAS20280
Model
Model XV19SD 1D7N (USA)
XV19SDC 1D7P (California)
XV19SD 1D7R (CDN)
XV19CTSD 2BH1 (USA)
XV19CTSDC 2BH2 (California)
XV19CTSD 2BH3 (CDN)
XV19CD 1US3/30BK (USA)
XV19CD 30BM (CDN)
XV19CDC 1US4/30BL (California)
XV19CSD 29PK (USA)
XV19CSD 29PM (CDN)
XV19CSDC 29PL (California)
Dimensions
Overall length XV19S(C)/ XV19CTS(C):
2580 mm (101.6 in)
XV19CS(C)/ XV19C(C):
2572 mm (101.3 in)
Overall width XV19S(C)/ XV19CTS(C):
1055 mm (41.5 in)
925 mm (36.4 in)
Overall height XV19S(C):
1105 mm (43.5 in)
XV19CTS(C):
1515 mm (59.6 in)
1165 mm (45.9 in)
Seat height XV19S(C)/ XV19CTS(C):
705 mm (27.8 in)
695 mm (27.4 in)
Wheelbase XV19S(C)/ XV19CTS(C):
1715 mm (67.5 in)
1799 mm (70.8 in)
Ground clearance XV19S(C)/ XV19CTS(C):
155 mm (6.10 in)
146 mm (5.75 in)
Minimum turning radius 3500 mm (137.8 in)
Weight
With oil and fuel XV19S(C)/ XV19C(C)(1US):
340.0 kg (750 lb)
XV19CTS(C):
369.0 kg (813 lb)
XV19CS(C)/ XV19C(C)(30B):
331.0 kg (730 lb)
2-1
Maximum load XV19S(C):

210 kg (463 lb)
XV19CTS(C):
181 kg (399 lb)
XV19C(C)(1US):
195 kg (430 lb)
204 kg (450 lb)
2-2
ENGINE SPECIFICATIONS
EAS20290
Engine
Engine type Air cooled 4-stroke, OHV
Displacement 1854.0 cm³
Cylinder arrangement V-type 2-cylinder
Bore × stroke 100.0 × 118.0 mm (3.94 × 4.65 in)
Compression ratio 9.48 :1
Starting system Electric starter
Fuel
Recommended fuel Premium unleaded gasoline only (Gasohol
(E10) acceptable)
Fuel tank capacity XV19S(C)/ XV19CTS(C):
17.0 L (4.49 US gal) (3.74 Imp.gal)
15.9 L (4.20 US gal) (3.50 Imp.gal)
Fuel reserve amount XV19S(C)/ XV19CTS(C):
3.0 L (0.79 US gal) (0.66 Imp.gal)
3.2 L (0.85 US gal) (0.70 Imp.gal)
Engine oil
Recommended brand YAMALUBE
Lubrication system Dry sump
Type SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 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 SAE 80 API GL-4 Hypoid gear oil
Quantity (disassembled) 0.60 L (0.63 US qt) (0.53 Imp.qt)
Quantity 0.55 L (0.58 US qt) (0.48 Imp.qt)
Oil filter
Oil filter type Cartridge (paper)
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09–0.19 mm (0.0035–0.0075 in)
Limit 0.26 mm (0.0102 in)
2-3
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.13 mm (0.0024–0.0051 in)
Limit 0.20 mm (0.0079 in)
Bypass valve opening pressure 80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20
kgf/cm²)
Relief valve operating pressure 600.0 kPa (87.0 psi) (6.00 kgf/cm²)
Transfer gear oil pump

Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.12 mm (0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.10–0.15 mm (0.0039–0.0059 in)
Limit 0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.04–0.09 mm (0.0016–0.0035 in)
Limit 0.160 mm (0.0063 in)
Spark plug(s)
Manufacturer/model NGK/DPR8EA-9
Manufacturer/model DENSO/X24EPR-U9
Spark plug gap 0.8–0.9 mm (0.031–0.035 in)
Cylinder head
Volume 80.90–84.90 cm³ (4.94–5.18 cu.in)
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Gear drive
Crankcase hole inside diameter 25.000–25.021 mm (0.9843–0.9851 in)
Camshaft journal diameter (crankcase side) 24.957–24.980 mm (0.9826–0.9835 in)
Camshaft to crankcase clearance 0.020–0.064 mm (0.0008–0.0025 in)
Camshaft cover hole inside diameter 28.000–28.021 mm (1.1024–1.1032 in)
Camshaft journal diameter (camshaft cover side) 27.957–27.980 mm (1.1007–1.1016 in)
Camshaft to camshaft cover clearance 0.020–0.064 mm (0.0008–0.0025 in)
Camshaft lobe dimensions
Intake A 42.532–42.632 mm (1.6745–1.6784 in)
Limit 42.432 mm (1.6705 in)
Intake B 35.950–36.050 mm (1.4154–1.4193 in)
Limit 35.850 mm (1.4114 in)
Exhaust A 42.530–42.630 mm (1.6744–1.6783 in)
Limit 42.430 mm (1.6705 in)
Exhaust B 35.950–36.050 mm (1.4154–1.4193 in)
2-4
Limit 35.850 mm (1.4114 in)
Rocker arm/rocker arm shaft

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

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

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

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

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

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

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

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

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

Limit 0.95 mm (0.0374 in)
Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in)
Limit 0.120 mm (0.0047 in)
2-7
Oil ring
B
T
Connecting rod
Oil clearance (using plastigauge®) 0.050–0.074 mm (0.0020–0.0029 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow
Crankshaft
Width A 105.80–106.20 mm (4.165–4.181 in)
Runout limit C 0.040 mm (0.0016 in)
Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in)
Big end radial clearance E 0.037–0.074 mm (0.0015–0.0029 in)
Limit 0.09 mm (0.0035 in)
Journal oil clearance (using plastigauge®) 0.030–0.060 mm (0.0012–0.0024 in)

Limit 0.10 mm (0.0039 in)
Clutch
Clutch type Wet, multiple-disc
Clutch release method Hydraulic inner push
Operation Left hand operation
Assembly width 48.0–48.8 mm (1.89–1.92 in)
Friction plate 3 thickness 2.90–3.10 mm (0.114–0.122 in)
Wear limit 2.80 mm (0.1102 in)
Plate quantity 3 pcs
Friction plate 1, 2 thickness 2.92–3.08 mm (0.115–0.121 in)
Wear limit 2.82 mm (0.1110 in)
Clutch plate 1 thickness 2.50–2.70 mm (0.098–0.106 in)
Plate quantity 1 pc
Clutch plate 2, 3 thickness 1.90–2.10 mm (0.075–0.083 in)
Clutch plate 4 thickness 1.90–2.10 mm (0.075–0.083 in)
Warpage limit 0.20 mm (0.0079 in)
Clutch spring free length 48.48 mm (1.91 in)
Limit 46.06 mm (1.81 in)
Spring quantity 3 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)
2-8
Transmission
Transmission type Constant mesh 5-speed
Primary reduction system Spur gear
Primary reduction ratio 72/51 (1.412)
Secondary reduction system Belt drive
Secondary reduction ratio XV19S(C)/ XV19CTS(C):
70/31 (2.258)
66/31 (2.129)
Operation Left foot operation
Gear ratio
1st 38/16 (2.375)
2nd 33/21 (1.571)
3rd 29/25 (1.160)
4th 26/28 (0.929)
5th 24/30 (0.800)
Main axle runout limit 0.08 mm (0.0032 in)
Drive axle runout limit 0.08 mm (0.0032 in)
Shifting mechanism
Shift mechanism type Guide bar
Shift fork guide bar bending limit 0.025 mm (0.0010 in)
Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in)
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Model/manufacturer 1D7/MITSUBISHI
Maximum consumption amperage 5.5 A
Output pressure 441.0–637.0 kPa (63.9–92.4 psi) (4.41–6.37
kgf/cm²)
Fuel injector
Model/quantity INP-101/2
Manufacturer NIPPON INJECTOR
Throttle body
Type/quantity AC43/2
Manufacturer MIKUNI
ID mark XV19SD/ XV19CTSD:
1D71 01
XV19SDC/ XV19CTSDC:
1D72 11
XV19CD/ XV19CSD:
5C71 00
XV19CDC/ XV19CSDC:
5C72 10
Throttle valve size #100
2-9
Throttle position sensor

Resistance 3.1–5.7 kΩ/blue-black
Output voltage (at idle) 0.63–0.73 V
Fuel injection sensor

Crankshaft position sensor resistance 248–372 Ω
Intake air pressure sensor output voltage 3.57–3.71 V
Engine temperature sensor resistance 0.90–1.10 kΩ at 100 °C (212 °F)
Idling condition
Engine idling speed 850–950 r/min
Intake vacuum 26.6–30.6 kPa (7.9–9.0 inHg) (200–230 mmHg)
Oil temperature 80.0–90.0 °C (176.00–194.00 °F)
Throttle cable free play 4.0–6.0 mm (0.16–0.24 in)
2-10
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Double cradle
Caster angle XV19S(C)/ XV19CTS(C):
31.30°
33.20°
Trail XV19S(C)/ XV19CTS(C):
152.0 mm (5.98 in)
102.0 mm (4.02 in)
Front wheel
Wheel type XV19S(C)/ XV19CTS(C)/ XV19CS(C)/
XV19C(C)(30B):
Cast wheel
XV19C(C)(1US):
Forged wheel
Rim size XV19S(C)/ XV19CTS(C):
18M/C × MT4.00
21M/C × MT3.50
Rim material Aluminum
Wheel travel 130.0 mm (5.12 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type XV19S(C)/ XV19CTS(C)/ XV19CS(C)/
XV19C(C)(30B):
Cast wheel
XV19C(C)(1US):
Forged wheel
Rim size XV19S(C)/ XV19CTS(C):
17M/C × MT5.50
18M/C × MT7.50
XV19C(C)(1US):
18M/C × 8.00
Rim material Aluminum
Wheel travel XV19S(C)/ XV19CTS(C):
110.0 mm (4.33 in)
90.0 mm (3.54 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
2-11
Size XV19S(C)/ XV19CTS(C):

130/70R18M/C 63H
120/70–21M/C 62H
Manufacturer/model XV19S(C)/ XV19CTS(C):
DUNLOP/D251F
XV19S(C)/ XV19CTS(C):
BRIDGESTONE/G851 RADIAL G
METZELER/880 MARATHON
Wear limit (front) 1.0 mm (0.04 in)
Rear tire
Type Tubeless
Size XV19S(C)/ XV19CTS(C):
190/60R17M/C 78H
210/40R18M/C 73H
Manufacturer/model XV19S(C)/ XV19CTS(C):
DUNLOP/D251
METZELER/880 MARATHON
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):
90–210 kg (198–463 lb)
XV19CTS(C):
90–181 kg (198–399 lb)
XV19CS(C)/ XV19C(C)
90–204 kg (198–450 lb)
High-speed riding
Front brake
Type Dual disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter × thickness 298.0 × 5.0 mm (11.73 × 0.20 in)
Brake disc thickness limit 4.5 mm (0.18 in)
Brake disc deflection limit 0.10 mm (0.0039 in)
Brake pad lining thickness (inner) 5.5 mm (0.22 in)
Brake pad lining thickness (outer) 5.5 mm (0.22 in)
2-12
Master cylinder inside diameter 14.00 mm (0.55 in)

Caliper cylinder inside diameter 27.00 mm (1.06 in)
Recommended fluid DOT 4
Rear brake
Type Single disc brake
Operation Right foot operation
Brake pedal position XV19S(C)/ XV19CTS(C):
110.0 mm (4.33 in)
93.0 mm (3.66 in)
Rear disc brake
Disc outside diameter × thickness XV19S(C)/ XV19CTS(C):
320.0 × 6.0 mm (12.60 × 0.24 in)
310.0 × 6.0 mm (12.20 × 0.24 in)
Brake disc thickness limit 5.5 mm (0.22 in)
Brake disc deflection limit XV19S(C)/ XV19CTS(C)/ XV19CS(C)/
XV19C(C)(30B):
0.15 mm (0.0059 in)
XV19C(C)(1US):
0.10 mm (0.0039 in)
Brake pad lining thickness (inner) 5.8 mm (0.23 in)
Brake pad lining thickness (outer) 5.8 mm (0.23 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Recommended fluid DOT 4
Steering
Steering bearing type Taper roller bearing
Lock to lock angle (left) 35.0°
Lock to lock angle (right) 35.0°
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm (5.12 in)
Fork spring free length XV19S(C)/ XV19CTS(C):
273.9 mm (10.78 in)
407.0 mm (16.02 in)
Limit XV19S(C)/ XV19CTS(C):
268.4 mm (10.57 in)
398.9 mm (15.70 in)
Collar length 230.0 mm (9.06 in)
Installed length XV19S(C)/ XV19CTS(C):
268.9 mm (10.59 in)
402.0 mm (15.83 in)
2-13
Spring rate K1 XV19S(C)/ XV19CTS(C):

10.0 N/mm (57.1 lbf/in) (1.02 kgf/mm)
8.34 N/mm (47.0 lbf/in) (0.84 kgf/mm)
Spring stroke K1 XV19S(C)/ XV19CTS(C):
0.0–30.0 mm (0.00–1.18 in)
130.0 mm (5.12 in)
12.0 N/mm (68.5 lbf/in) (1.22 kgf/mm)
30.0–130.0 mm (1.18–5.12 in)
Inner tube outer diameter 46.0 mm (1.81 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available No
Recommended oil Yamaha fork oil 10WT
Quantity XV19S(C)/ XV19CTS(C):
571.0 cm³ (19.31 US oz) (20.10 Imp.oz)
755.0 cm³ (25.53 US oz) (26.58 Imp.oz)
Level XV19S(C)/ XV19CTS(C):
124.0 mm (4.88 in)
117.0 mm (4.61 in)
Rear suspension
Type Swingarm (link suspension)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel XV19S(C)/ XV19CTS(C):
50.0 mm (1.97 in)
40.0 mm (1.57 in)
Spring free length XV19S(C)/ XV19CTS(C):
180.0 mm (7.09 in)
187.0 mm (7.36 in)
176.4 mm (6.94 in)
183.3 mm (7.22 in)
Installed length XV19S(C):
171.0 mm (6.73 in)
XV19CTS(C):
165.0 mm (6.50 in)
172.0 mm (6.77 in)
176.50 N/mm (1007.82 lbf/in) (18.00 kgf/mm)
186.20 N/mm (1063.18 lbf/in) (18.99 kgf/mm)
2-14

0.0–50.0 mm (0.00–1.97 in)
0.0–40.0 mm (0.00–1.57 in)
Optional spring available No
Enclosed gas/air pressure (STD) 0.98 MPa (139.4 psi) (9.8 kgf/cm²)
Spring preload adjusting positions Installed spring length
Minimum XV19S(C)/ XV19CTS(C):
162.0 mm (6.38 in)
163.0 mm (6.42 in)
Standard XV19S(C):
171.0 mm (6.73 in)
XV19CTS(C):
165.0 mm (6.50 in)
172.0 mm (6.77 in)
Maximum XV19S(C)/ XV19CTS(C):
171.0 mm (6.73 in)
172.0 mm (6.77 in)
Swingarm
Swingarm end free play limit (radial) 1.0 mm (0.04 in)
Swingarm end free play limit (axial) 1.0 mm (0.04 in)
Drive belt
Model/manufacturer UBD-0732/GATES CORPORATION
Drive belt slack (on the sidestand) 7.5–13 mm (0.30–0.51 in)
Drive belt slack (on a suitable stand) 14–21 mm (0.55–0.83 in)
2-15
ELECTRICAL SPECIFICATIONS
EAS20310
Voltage
System voltage 12 V
Ignition system
Ignition system Transistorized coil ignition (digital)
Advancer type Electrical
Ignition timing (B.T.D.C.) 10.0°/900 r/min
Engine control unit

Model/manufacturer XV19S(C)/ XV19CTS(C):
F008T85371/MITSUBISHI
F008T85671/MITSUBISHI
Ignition coil
Model/manufacturer 2JN/YAMAHA
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16–2.64 Ω
Secondary coil resistance 8.64–12.96 kΩ
Spark plug cap

Material Resin
Resistance 10.0 kΩ
AC magneto
Model/manufacturer F4T38971/MITSUBISHI
Standard output 14.0 V 32.0 A 5000 r/min
Stator coil resistance 0.112–0.168 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer FH020AA/SHINDENGEN
No load regulated voltage 14.2–14.8 V
Rectifier capacity 50.0 A
Withstand voltage 40.0 A
Battery
Model GT14B-4
Voltage, capacity 12 V, 12.0 Ah
Manufacturer GS YUASA
Ten hour rate amperage 1.20 A
Headlight
Bulb type Halogen bulb
Bulb voltage, wattage × quantity

Low beam headlight XV19S(C)/ XV19CTS(C):
12 V, 51.0 W × 1
High beam headlight XV19S(C)/ XV19CTS(C):
12 V, 55.0 W × 1
2-16
Headlight XV19CS(C)/ XV19C(C):

12 V, 60.0 W/55.0 W × 1
Tail/brake light LED
Front turn signal/position light 12 V, 23 W/8.0 W × 2
Rear turn signal light 12 V, 21.0 W × 2
License plate light XV19S(C)/ XV19CTS(C):
12 V, 5.0 W
12 V, 3.8 W × 2
Meter lighting LED
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Fuel level warning light LED
Engine trouble warning light LED
Electric starting system

System type Constant mesh
Starter motor
2C5/YAMAHA
1D7/YAMAHA
Power output 0.90 kW
Armature coil resistance 0.0081–0.0099 Ω
Brush overall length 11.3 mm (0.44 in)
Limit 7.60 mm (0.30 in)
Brush spring force 7.36–11.04 N (26.49–39.74 oz) (750–1126 gf)
Commutator diameter XV19S(C)/ XV19CTS(C):
28.0 mm (1.10 in)
28.5 mm (1.12 in)
27.0 mm (1.06 in)
27.5 mm (1.08 in)
Mica undercut (depth) 1.50 mm (0.06 in)
Starter relay
Model/manufacturer RC19–032/MATSUSHITA
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
Performance 95–115 dB/2m
2-17
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
1D7/YAMAHA
5C7/YAMAHA
Sender unit resistance (full) 9–11 Ω
Sender unit resistance (empty) 213.0–219.0 Ω
Starting circuit cut-off relay

Model/manufacturer G8R-30Y-V3/OMRON
Headlight relay
Model/manufacturer ACM33211M05/MATSUSHITA
Fuel pump relay

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

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

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

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

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

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

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

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

Engine oil pump driven gear
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
stopper bolt
Oil pipe 3 bolt M6 5 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil pump bolt (crankcase) M8 3 24 Nm (2.4 m·kg, 17 ft·lb)
2-20
TIGHTENING TORQUES
Thread
size
Oil pump housing cover 1 screw
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
(crankcase)
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
(crankcase)
Throttle body joint clamp screw M5 2 3 Nm (0.3 m·kg, 2.2 ft·lb)
Pressure regulator bolt M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Intake manifold assembly bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel pipe bolt M12 2 30 Nm (3.0 m·kg, 22 ft·lb)
Rear exhaust pipe joint nut M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Rear exhaust pipe, rear exhaust
pipe joint cover and rear exhaust M8 2 24 Nm (2.4 m·kg, 17 ft·lb)
pipe joint nut
Front exhaust pipe nut M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Front exhaust pipe and rear ex-
M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
haust pipe bolt
Rear exhaust pipe and muffler
M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
bolt
Locknut (EXUP cable) M6 2 6 Nm (0.6 m·kg, 4.3 ft·lb)
EXUP valve pulley cover bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear exhaust pipe joint cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Muffler and frame bolt*2 M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Muffler and muffler bracket bolt*1 M8 3 29 Nm (2.9 m·kg, 21 ft·lb)
Muffler and muffler bracket bolt*2 M8 2 29 Nm (2.9 m·kg, 21 ft·lb) LT
Muffler bracket and frame bolt M10 2 53 Nm (5.3 m·kg, 38 ft·lb) LT
O2 sensor M18 1 15 Nm (1.5 m·kg, 11 ft·lb)

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

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

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

M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
iter)
Oil gallery bolt M8 4 20 Nm (2.0 m·kg, 14 ft·lb) LT
Engine oil drain bolt (crankcase) M14 2 32 Nm (3.2 m·kg, 23 ft·lb)

Stator coil lead holder screw M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Crankshaft position sensor lead

M6 6 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
holder screw
2-21
TIGHTENING TORQUES
Thread
size
Clutch cover damper plate
M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
screw*1
Camshaft cover bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)
Generator cover damper bolt M5 3 5 Nm (0.5 m·kg, 3.6 ft·lb) LT
Engine oil filler plug M20 1 10 Nm (1.0 m·kg, 7.2 ft·lb)

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

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

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

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

M10 1 40 Nm (4.0 m·kg, 29 ft·lb)
sembly nut
Transfer gear case oil pump as-
M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
sembly bolt
Oil pump housing screw (transfer
M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
gear case)
Transfer gear oil check bolt M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
2-22
TIGHTENING TORQUES
Thread
size
Transfer gear case bolt M10 4 50 Nm (5.0 m·kg, 36 ft·lb)
Dipstick joint bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Drive pulley case bolt M12 8 70 Nm (7.0 m·kg, 50 ft·lb)

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

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

Oil cooler bracket bolt*1 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Oil cooler hose bolt*1 M6 8 7 Nm (0.7 m·kg, 5.1 ft·lb)
Clutch hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Clutch pipe union bolt M10 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch pipe holder bolt*1 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Clutch pipe holder bolt*2 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Clutch pipe joint nut M10 1 19 Nm (1.9 m·kg, 13 ft·lb)
*1 For XV19S(C)/ XV19CTS(C)
*2 For XV19CS(C)/ XV19C(C)
TIP
• 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).
2-23
TIGHTENING TORQUES
Cylinder head tightening sequence:
A B
1 4
3 2
3 2
1 4
A. Front cylinder
B. Rear cylinder
2-24
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

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

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

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

Horn 1 bolt*3 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Horn 2 bolt*3 M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
ISC (idle speed control) unit bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
2-25
TIGHTENING TORQUES
Thread
size
ISC (idle speed control) unit
M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
bracket bolt
Pivot shaft nut M18 1 125 Nm (12.5 m·kg, 90 ft·lb)
Relay arm nut (relay arm and
M12 1 59 Nm (5.9 m·kg, 43 ft·lb)
swingarm)
Relay arm nut (relay arm and
M12 1 59 Nm (5.9 m·kg, 43 ft·lb)
connecting arm)
Rear shock absorber assembly
M10 1 40 Nm (4.0 m·kg, 29 ft·lb)
nut (rear side)
Rear shock absorber assembly
M12 1 59 Nm (5.9 m·kg, 43 ft·lb)
nut (front side)
Upper drive belt cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Lower drive belt cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake hose guide bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Upper bracket pinch bolt*1, 2 M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Upper bracket pinch bolt*3 M8 4 19 Nm (1.9 m·kg, 13 ft·lb)

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

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

Lower ring nut (initial tightening
M30 1 52 Nm (5.2 m·kg, 37 ft·lb) See TIP.
torque)
Lower ring nut (final tightening
M30 1 18 Nm (1.8 m·kg, 13 ft·lb) See TIP.
torque)
2-26
TIGHTENING TORQUES
Thread
size
Hose guide and lower handlebar
M10 2 32 Nm (3.2 m·kg, 23 ft·lb)
holder nut*1, 2
Hose guide and lower handlebar
M12 2 40 Nm (4.0 m·kg, 29 ft·lb)
holder nut*3
Front brake master cylinder hold-
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
er bolt
Front brake hose union bolt (front
M10 1 30 Nm (3.0 m·kg, 22 ft·lb)
brake master cylinder side)
Clutch master cylinder holder bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Grip end M16 2 23 Nm (2.3 m·kg, 17 ft·lb)
Lower handlebar holder nut*1, 2 M10 2 50 Nm (5.0 m·kg, 36 ft·lb) LT
Upper bracket cover bolt*1, 2 M8 2 19 Nm (1.9 m·kg, 13 ft·lb) LT
Upper bracket cover bolt*1, 2 M8 2 16 Nm (1.6 m·kg, 11 ft·lb) LT
Front brake hose guide and front

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

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

Front fender bolt M8 6 16 Nm (1.6 m·kg, 11 ft·lb) LT
Fuel sender bolt M5 4 4 Nm (0.4 m·kg, 2.9 ft·lb)

Fuel tank bracket bolt (front side) M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Fuel tank bracket 2 bolt (front
M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
side)*3
Fuel tank bracket nut (rear side) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Sub-fuel tank bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Rider seat bracket bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb) LT
Fuel tank and fuel tank bracket

M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt (front side)
Fuel tank and fuel tank bracket
M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
bolt (rear side)
2-27
TIGHTENING TORQUES
Thread
size
Meter cover bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel pump bolt M5 6 5 Nm (0.5 m·kg, 3.6 ft·lb)
Fuel return pipe holder bolt*1, 2 M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel return pipe holder bolt*3 M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Fuel tank breather/overflow pipe

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

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

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

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

M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
relay side)*1, 2
Positive battery lead bolt (starter
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
relay side)*1, 2
Starter motor lead bolt (starter
M6 1 5 Nm (0.5 m·kg, 3.6 ft·lb)
relay side)*3
2-28
TIGHTENING TORQUES
Thread
size
Positive battery lead bolt (starter
M6 1 5 Nm (0.5 m·kg, 3.6 ft·lb)
relay side)*3
Rear fender bracket and frame
M10 4 40 Nm (4.0 m·kg, 29 ft·lb)
bolt
Rear fender bracket and frame
M10 2 40 Nm (4.0 m·kg, 29 ft·lb) LT
bolt*1, 2
Rear fender bracket and rear
M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
fender bolt
Passenger seat bolt M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Rider seat bracket assembly and
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
seat lock assembly bolt
Tool kit and battery box bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Pressure regulator bracket
M6 2 13 Nm (1.3 m·kg, 9.4 ft·lb)
bolt*1, 2
Pressure regulator bracket bolt*3 M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
Cylinder-#1 ignition coil cover
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
bolt*1, 2
Cylinder-#1 ignition coil bracket
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt*1, 2
Right ignition coil cover bolt*3 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Right ignition coil bracket bolt*3 M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)

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

M10 4 48 Nm (4.8 m·kg, 35 ft·lb) LT
and right)
Passenger footrest bolt (left and
M10 4 48 Nm (4.8 m·kg, 35 ft·lb) LT
right)
Rear brake master cylinder
bracket and rear brake master M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
cylinder bolt
Rear brake master cylinder
M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
bracket and frame bolt
Rear brake master cylinder cover
M8 2 16 Nm (1.6 m·kg, 11 ft·lb)
bolt
Locknut (brake rod) M8 1 16 Nm (1.6 m·kg, 11 ft·lb)
Brake fluid reservoir and frame
M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
bolt
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kg, 22 ft·lb)
Rear brake hose holder bolt*1, 2 M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake hose holder bolt*3 M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Shift pedal shaft bracket bolt*1, 2 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)
2-29
TIGHTENING TORQUES
Thread
size
Shift pedal bolt (toe side)*1, 2 M6 1 14 Nm (1.4 m·kg, 10 ft·lb)
Shift pedal bolt (heel side)*1, 2 M6 1 13 Nm (1.3 m·kg, 9.4 ft·lb)
Shift pedal bolt*3 M8 1 30 Nm (3.0 m·kg, 22 ft·lb) LT
Lower bracket pinch bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb)

Cap bolt M43 2 23 Nm (2.3 m·kg, 17 ft·lb)
Damper rod assembly M12 2 40 Nm (4.0 m·kg, 29 ft·lb) LT
Lower front fork cover nut*1, 2 M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb) LT
Stake
Drive pulley nut M22 1 140 Nm (14.0 m·kg, 100 ft·lb)
E
Drive pulley cover damper plate

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

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

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
O-rings LS
Bearings E
Cylinder head nuts and washers E
Connecting rod small end and big end E
Crankshaft journals M
Piston surfaces E
Piston pins E
Connecting rod bolts M
Balancer idle gear inner surface and balancer idle gear shaft E
Left balancer driven gear inner surface M
Right balancer M
Gasket (left balancer driven gear housing) LS
Flange bolts (left balancer drive gear and right balancer driven gear) E
Camshaft cam lobes and camshaft journals M
Flange bolt (camshaft gear) E
Valve push rod end balls E
Valve stems (intake and exhaust) M
Valve stem ends (intake and exhaust) E
Valve lifters E
Rocker arms E
Rocker arm shafts E
Camshaft (front and rear cylinders) E
Oil pump rotors (inner and outer) and oil pump housing LS
Oil pump driven gear shaft E
Oil filter bolt E
Crankcase stud bolt ends E
Starter clutch idle gear shaft E
Starter clutch idle gear inner surface E
Starter clutch gear inner surface and outer surface E
Generator shaft journal E
Primary driven gear inner surface E
Clutch push rods and ball LS
2-32

Clutch boss nut and washer E
Transmission gears (wheel and pinion) and collar M
Drive pulley nut and conical spring washer E
Middle drive gear nut and conical spring washer E
Shift forks and shift fork guide bars E
Shift drum E
Shift shaft and shift shaft oil seal LS
Shift fork pawl M
Yamaha bond
Crankcase mating surface No.1215 (Three Bond
No.1215®)
Yamaha bond
Stator coil lead grommet No.1215 (Three Bond
No.1215®)
Yamaha bond
Crankshaft position sensor lead grommet No.1215 (Three Bond
No.1215®)
2-33
EAS20380
CHASSIS
Steering bearings and upper bearing dust cover lip LS
Lower bearing dust seal lip LS
Lower bracket steering shaft*1 LS
Steering stem bolt*1 LS
Front wheel oil seal lips (left and right) LS
Rear wheel oil seal lips LS
Rear wheel drive hub oil seal lip LS
Rear wheel drive hub mating surface LS
Tube guide (throttle grip) inner surface and throttle cables LS
Brake lever pivoting point and metal-to-metal moving parts S
Clutch lever pivoting point and metal-to-metal moving parts S
Brake pedal shaft pivoting point LS
Shift pedal pivoting point LS
Passenger footrest pivoting point and ball LS
Sidestand pivoting point and metal-to-metal moving parts LS
Dowel pins (rear fender stay) LS
Pivot shaft LS
Swingarm pivoting point, collar flange circumference, and oil seal inner
LS
surface
Rear shock absorber bushings and O-rings LS
Swingarm, relay arm bearings, and oil seal lips LS
Connecting arm bushings and O-rings LS
Rear wheel axle LS
Clutch master cylinder push rod pin and contact surface S
2-34
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390

EAS20400
ENGINE OIL LUBRICATION CHART
22 21 20 23
19 18
17
16
15 9
8
14
11
14
9
10 12
13
8 7
2
3
2-35
1. Oil strainer (transfer gear case)

2. Oil pump
3. Oil tank
4. Drive axle
5. Main axle
6. Oil strainer (crankcase)
7. Balancer
8. Front cylinder head cover
9. Rear cylinder head cover
10. Rear cylinder camshaft
11. Front cylinder camshaft
12. Rear valve lifter case
13. Front valve lifter case
14. Push rod
15. Crankshaft
16. Camshaft sprocket cover
17. Generator shaft
18. Generator cover
19. Left crankcase
20. Oil filter cartridge bracket
21. Oil filter cartridge
22. Right crankcase
23. Oil cooler (for XV19S(C)/ XV19M(C)/
XV19CTS(C)/ XV19CTM(C))
2-36
EAS20410
LUBRICATION DIAGRAMS
2 9
10
A-A
B-B
3
A 4
B
D
A
1
B
E
E
C
D
7 6 5
D-D C
11
E-E
2-37
1. Oil tank
2. Dipstick
3. Oil pipe 2
4. Oil delivery pipe 1
5. Oil filter cartridge
7. Oil pipe 3
8. Oil pipe 4
9. Oil pipe 5
10. Oil strainer (oil tank)
2-38
3
3
A
2 4
6
D 7
C
C
D
B
1
B-B
5
B
6
7
D-D C-C
2-39
1. Valve lifter
2. Push rod
3. Rocker arm shaft
4. Oil pipe 1
5. Crankshaft
6. Oil pipe (“F” mark)
7. Oil pipe (“R” mark)
2-40
A A
A-A
2-41
1. Oil pipe 1
2. Oil pump
4. Joint pipe
2-42
1 2
4 3
2-43
1. Main axle
2. Drive axle
4. Oil pump
A. To the oil filter cartridge
2-44
1
5
B-B
B A
A
2-45
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
2-46
2-47
1. Transfer gear oil pump

2. Middle driven shaft
2-48
CABLE ROUTING (for XV19S(C)/ XV19CTS(C))
EAS20430

1 5 5 6 7
D
B-B C-C D D-D
2 A 3 4 5
1
1 5
A C
E
C B C 6
D 7
A
C E
B D
B
6 7
F
F
F-F
5 1
6
7
G G
E
F
11 8
10 9
2-49
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. Face the catch of the holder rearward.
E. Fasten the rear brake light switch lead with a plastic
locking tie. Point 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 a plastic
downward, and then cut off the excess end of the
tie.
H. Route the throttle cable (accelerator cable) over the
throttle cable (decelerator cable).
2-50
5 1
4 G 9
A 2 10
B
E C
3
D
G I
E
F
G 6 J
8
H
F
F 7
11
E
A 2
B
D
C B-B
1 B
D 4
1 2
12 2
8 3
6
1
K 2
3
G-G F-F D-D
L
E-E
2-51
1. Main switch lead

3. Wire harness
5. Air temperature sensor lead
6. Front left turn signal/position light lead
7. Headlight lead
8. Front right turn signal/position light lead
9. Headlight coupler (high beam)
10. Headlight coupler (low beam)
12. Main switch
A. View with headlight lens unit removed.
B. Place the joint coupler behind the leads.
C. Place the sections of the handlebar switch leads
that are not covered by their protective sleeves in
the rear of the headlight housing.
D. Fasten the headlight leads, front turn
signal/position light leads, and accessory light lead
with the holders along the side of the headlight
housing.
E. Place the headlight leads, front turn signal/position
light leads, and accessory light lead near the base
of the holder.
F. 30 mm (1.18 in)
G. View from rear of headlight lens unit
H. Less than 20 mm (0.79 in). Fasten the headlight
lead (low beam) with the holder, making sure to
fasten the protective sleeve of the lead, not the lead
itself.
I. Route the headlight lead (high beam) between the
headlight coupler (low beam) and the stay.
J. Route the headlight lead (high beam) behind the
headlight lead (low beam).
K. Secure the plastic band by inserting the projection
on the band into the hole in the headlight housing.
L. Point the end of the plastic band downward.
2-52
24 25 26
U V X
2 W Z
AH Y
N 1 T
S 27
R 3
O
T 4 28
23 22 AG
21 P R 3
29 AA
4
B-B C-C 30
Q AB AF AE AD AC AB
A D
10
6 B C 7 8 9 11
A D 12
5 C
4
3 B E
2
1 C
B
F
D
A G
H
M
13
J
I I
E E
20 K 14
19 H G
15
F
L
G
F
I 18 17 16 I
X
AI
15 15 15 15
AJ
I-I H G-G F-F E-E
2-53
1. EXUP servo motor N. Fasten the cylinder-#1 left and right ignition coil
2. Fuse box leads and wire harness to the guide on the engine
bracket (right upper side) with a plastic locking tie.
3. Wire harness Be sure to position the leads and wire harness to
4. Fuel outlet hose the inside of the guide. Cut off the excess end of
5. Cylinder-#1 right spark plug cap the plastic locking tie.
6. Cylinder-#1 right ignition coil O. Fasten the cylinder-#1 left and right ignition coil
leads and sub-wire harness 2 to the guide on the
7. Sub-wire harness 3 coupler engine bracket (right upper side) with a plastic
8. Fuel sender (fuel tank) coupler locking tie. Be sure to position the leads and sub-
9. Meter assembly coupler wire harness to the inside of the guide. Align the
plastic locking tie with the purple tape on sub-wire
10. Front brake hose harness 2. Cut off the excess end of the plastic
11. Throttle cable (accelerator cable) locking tie.
12. Throttle cable (decelerator cable) P. To the fuel injectors, engine temperature sensor,
13. Cylinder-#2 right spark plug cap and throttle position sensor
14. Cylinder-#1 left ignition coil Q. To the ignition coil
15. Clutch pipe R. Outside of frame
16. Neutral switch lead S. Face the buckle of the plastic locking tie upward
with the end pointing outward. Cut off the excess
17. Stator coil lead end of the plastic locking tie.
18. Speed sensor lead T. Inside of frame
19. O2 sensor lead U. Fasten the fuel outlet hose and wire harness to the
20. EXUP cable frame with a plastic locking tie as shown in the
illustration. When installing the plastic locking tie,
21. Sub-wire harness 2 coupler insert the end of the tie through the lower opening
22. Cylinder-#1 right spark plug lead in the buckle of the tie, and then insert the end
23. Cylinder-#1 left spark plug lead through the upper opening.
24. ISC (idle speed control) unit inlet hose V. Make sure that the buckle of the plastic locking tie
does not protrude to the outside of the line shown
25. Cylinder-#2 ISC (idle speed control) unit outlet in the illustration.
hose
W. Point the end of the plastic locking tie outward,
26. Cylinder-#1 ISC (idle speed control) unit outlet angled downward, as shown in the illustration. Cut
hose off the excess end of the plastic locking tie. Make
27. Sub-wire harness 3 sure that the cut end of the plastic locking tie does
28. Cylinder-#2 right spark plug lead not contact the engine.
29. Sub-wire harness 4 coupler X. To the wire harness
30. Cylinder-#2 left spark plug lead Y. To the cylinder-#2 right spark plug
A. Fasten the cylinder-#1 left and right spark plug Z. Right side
leads, fuel outlet hose, wire harness, and fuel tank AA.Position the sub-wire harness 4 coupler between
damper with a plastic locking tie. Install the plastic the cylinder-#2 right spark plug lead and the
locking tie in the middle slot of the fuel tank cylinder-#1 ISC (idle speed control) unit outlet
damper. hose.
B. Fasten sub-wire harness 2 with a plastic locking AB.Point the ends of the hose clamp outward, angled
tie. 45° downward.
C. Fasten the wire harness and sub-wire harness 3 AC.Route the cylinder-#2 right spark plug lead under
with the plastic band. If the sub-wire harness 3 sub-wire harness 4.
coupler is positioned within the range shown in the
illustration, the plastic band may be installed AD.Route sub-wire harness 3, sub-wire harness 4,
around the coupler. and the cylinder-#2 right spark plug lead over the
cylinder-#1 ISC (idle speed control) unit outlet
D. Align the positioning tape on the wire harness with hose.
the top of the frame.
AE.Point the ends of the hose clamp downward.
E. Route the throttle cables behind the front brake
hose. AF. Route the cylinder-#2 left spark plug lead under
the cylinder-#2 ISC (idle speed control) unit outlet
F. Make sure that the wire harness is not twisted hose.
between the fuel tank and the headlight assembly.
AG.Left side
G. Position the cylinder-#2 left and right spark plug
leads, sub-wire harness 2 coupler, and sub-wire AH.To the cylinder-#2 left spark plug
harness 4 coupler on top of the guide. AI. Install the clutch pipe onto the clutch release
H. Route sub-wire harness 3 over the wire harness. cylinder, making sure that the pipe contacts the
projection on the cylinder.
I. Fasten the stator coil lead with a plastic locking tie.
Point the end of the plastic locking tie outward, and AJ. To the O2 sensor
then cut off the excess end of the tie.
J. To the neutral switch
K. To the speed sensor
L. To the brake fluid reservoir
M. Install the O2 sensor coupler completely onto the
O2 sensor bracket.
2-54
C
A B A B 2 3 4 5
D
A
B
E
6 F
21 G
F F
E
20
22
19 7
18 U 8
T H
C I
17 9
S
P C D
J
R 16 Q 15 O N 14 N M 13 12 L 11 10 K
26 27 28 29 30 31 32 24
AB 18 15 16 25
23
33
C-C
X G V
G 24
A-A
AC W 3
X X
2
AD
1
Z Y
36 D
E
B-B
34
16 15
C
AA 35 18
S F-F
Q C
R N
2-55
1. Clutch hose K. Fasten the stator coil lead and rectifier/regulator

2. Throttle cable (decelerator cable) lead with a plastic locking tie. Point the end of the
plastic locking tie outward, and then cut off the
3. Throttle cable (accelerator cable) excess end of the tie.
4. Cylinder-#2 left spark plug cap L. Fasten the lean angle sensor lead, starter motor
5. Cylinder-#1 left spark plug cap lead, horn 1 lead, rear brake light switch lead, and
6. Sub-wire harness 1 sidestand switch lead with the holder.
7. Rectifier/regulator M. Route the starter motor lead, horn 1 lead, rear
brake light switch lead, and sidestand switch lead to
8. Crankshaft position sensor lead the inside of the frame boss.
9. Stator coil lead N. Fasten the starter motor lead, horn 1 lead, rear
10. Rectifier/regulator lead brake light switch lead, and sidestand switch lead
11. Lean angle sensor with a plastic locking tie. Point the end of the plastic
locking tie outward, and then cut off the excess end
12. Horn 2 lead of the tie.
13. Horn 2 O. Fasten the starter motor lead, horn 1 lead, and rear
14. Sidestand switch brake light switch lead with a plastic locking tie.
15. Horn 1 lead Point the end of the plastic locking tie outward. Be
sure to install the plastic locking tie behind the
16. Rear brake light switch lead frame cross member and to fasten the rear brake
17. Horn 1 light switch lead at the white tape.
18. Starter motor lead P. Route the starter motor lead, horn 1 lead, and rear
19. Clutch pipe brake light switch lead along the frame in the area
shown in the illustration, making sure not to cross
20. Fuel tank breather/overflow hose the leads.
21. Rollover valve Q. Align the positioning tape on the starter motor lead
22. Front brake hose with the engine mounting bolt (front lower side).
23. Headlight assembly R. Route the fuel tank breather/overflow hose through
24. Front fork the horn 1 bracket, making sure to position the end
of the hose as shown in the illustration.
25. Frame
S. Fasten the starter motor lead, horn 1 lead, and rear
26. Main fuse brake light switch lead with a plastic locking tie.
27. Diode Point the end of the plastic locking tie inward.
28. Relay unit T. Fasten the horn 1 lead, rear brake light switch lead,
29. Turn signal relay and starter motor lead with a plastic locking tie.
Point the end of the plastic locking tie inward, and
30. Headlight relay then cut off the excess end of the tie.
31. Starter relay U. Route the horn 1 lead to the rear of the starter
32. EXUP servo motor motor lead.
33. EXUP cable V. Route the throttle cables through the cable guides
34. Speed sensor lead as shown in the illustration.
35. Wire harness W. Install the lead cover, making sure not to pinch the
stator coil lead and rectifier/regulator lead.
36. Canister (for California only)
X. Pass a plastic locking tie through the hole in the
A. Route the throttle cables to the inside of the clutch battery box projection, and then fasten the wire
hose. harness with the tie.
B. Route the cylinder-#2 left spark plug lead through Y. Fasten the stator coil lead at the white tape with a
the guide. plastic locking tie.
C. 30–40 mm (1.18–1.57 in) Z. Fasten the stator coil lead with a plastic locking tie.
D. Fasten the crankshaft position sensor lead, neutral AA.Forward
switch lead, and sidestand switch lead with the
holders. AB.Route the wire harness along the side of the fuse
box/starter relay bracket.
E. Fasten the starter motor lead, speed sensor lead,
and wire harness with the holders. AC.For California only
F. Route sub-wire harness 1 to the inside of the AD.Route the horn 1 lead to the rear of the canister.
frame.
G. To the tail/brake light
H. Fasten the starter motor lead, horn 1 lead, rear
brake light switch lead, sidestand switch lead,
rectifier/regulator lead and crankshaft position
sensor lead with a plastic locking tie.
I. Make sure that there is no slack in the stator coil
lead and rectifier/regulator lead in the area shown
in the illustration.
J. Fasten the stator coil lead with a plastic locking tie.
Point the end of the plastic locking tie outward, and
2-56
2
A
L 22 20 4
1
14 16
B
4 8 21 4
A-A C-C
A A C
K
13 3
12
4
J
D 16 17 4
18
15
D
E M
B N
I D B 24
19 25
C C 20
F D-D
H 21
5 23 22 8
11 6 B-B
7
10
G 9 8
U S O
V 28
W
T
T 5 P
W
27
26 R 9 Q
2-57
1. Fuel sender (fuel tank) coupler L. Fasten the air filter case damper with the plastic
2. Meter assembly coupler locking tie so that the rubber part of the damper
contacts the frame. Be sure to pass the plastic
3. Cylinder-#1 right spark plug cap locking tie between the air filter case damper and
4. Wire harness the frame.
5. Negative battery lead M. Inside of frame
6. EXUP servo motor lead N. Outside of frame
7. Fuse box O. View with tray removed
8. Starter motor lead P. Route the negative battery lead under the starter
9. Positive battery lead motor lead and positive battery lead.
10. Sub-wire harness 1 Q. Route the positive battery lead (main fuse to
starter relay) over the tray.
R. Route the positive battery lead (battery to starter
12. Intake air pressure sensor coupler relay) under the tray.
13. Cylinder-#1 left spark plug cap S. View with tray installed
14. Sub-wire harness 3 T. To the tail/brake light
15. Air vent hose (fuel pump to fuel hose joint) U. View with ECU removed
16. Neutral switch lead V. Wrap the protective covering around the couplers
17. Fuel outlet hose (crankshaft position sensor coupler, auxiliary DC
18. Frame jack coupler, neutral switch coupler, sub-wire
harness 1 coupler, speed sensor coupler, and
19. Oil tank sidestand switch coupler) and the wire harness.
20. Crankshaft position sensor lead W. When installing the ECU, be sure not to pinch the
21. Speed sensor lead leads in the areas shown in the illustration with
22. Sidestand switch lead oblique lines.
23. Sub-fuel tank
24. Fuel hose (fuel tank to fuel hose joint)
25. Fuel return hose (fuel return pipe to 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. Fasten the wire harness, sub-wire harness 3, and
air filter case damper with a plastic locking tie.
Point the end of the plastic locking tie inward. Do
not cut off the excess end of the plastic locking tie.
C. Fasten the wire harness and air filter case damper
with a plastic locking tie. Point the end of the plastic
locking tie inward. Do not cut off the excess end of
the plastic locking tie.
D. Route the wire harness along the frame.
E. Fasten the wire harness at the white tape with the
plastic band. Align the plastic band with the rib on
the tray. Point the end of the plastic band inward.
F. Route the crankshaft position sensor lead,
sidestand switch lead, neutral switch lead, starter
motor lead and speed sensor lead under the fuel
outlet hose.
G. Fasten the crankshaft position sensor lead, neutral
switch lead, sidestand switch lead, speed sensor
lead, and wire harness with the plastic band. Point
the end of the plastic band inward.
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 band. The end of the
plastic band should be under the fuel hose joint,
pointing inward.
J. Route the intake air pressure sensor lead so that it
does not protrude past the top of the frame.
K. Fasten the fuel tank damper with a plastic locking
tie. Install the plastic locking tie in the middle slot of
the fuel tank damper.
2-58
2 2
1 A
H
A
B
B
C 1
I
1
C
B
G
3
5
D D
D
D
E
E
F
E
E
4 F E
K
1
M 3
1
L
4
E-E D-D
4
F
C
2-59
1. Brake fluid reservoir hose

3. O2 sensor lead
4. Rear brake hose
5. EXUP cable
A. Point the ends of the hose clamp upward.
B. Install the brake fluid reservoir hose with its white
paint mark facing upward.
C. Point the ends of the hose clamp forward.
D. Position the plastic locking tie 10–15 mm (0.39–
0.59 in) from the end of the protector. Face the
buckle of the plastic locking tie upward.
E. Align the end of the protector with the end of the
pipe section of the rear brake hose.
F. Fasten the grommet on the rear brake hose with
G. Fasten the EXUP cable and brake fluid reservoir
hose with the holder. Make sure that the portion of
the holder fastening the hose is facing rearward.
H. Install the rear brake light switch so that the rear
brake light switch lead is routed inward.
I. Align the paint mark on the brake hose joint with
the paint mark on the rake fluid reservoir hose.
J. To the rear brake hose
K. To the brake fluid reservoir
L. Install the holder as shown in the illustration.
M. Route the brake fluid reservoir hose through the
passage in the protector, wrap the protector
around the rear brake hose, and then fasten the
protector with the plastic locking tie.
2-60
2
1
3
G
4
5
6
7
A
17
23
18 D C 8
12
11 9
19 E
16 15 B
22 10
H F
13 A
14
21
20 I 8
J
6 B
I
M N
L
K
V W
U 24
X O
T
R 25
5
4 Q 6
S
5
M
7
H 11 P
A 4
Y G
7
21 11
Z 26 8
24
27
C
C
C-C
B
28
2-61
1. Fuel tank breather hose Q. Face the crimped section of the hose clamp
2. Fuel sender (fuel tank) upward. Position the projections on the hose clamp
as shown in the illustration.
3. Fuel tank
R. Align the yellow paint mark on the fuel hose (fuel
4. Fuel hose (fuel tank to fuel hose joint) tank to fuel hose joint) with the round indentation on
5. Fuel return hose (fuel return pipe to sub-fuel tank) the bend in the fuel hose joint.
6. Air vent hose (fuel hose joint to fuel tank) S. Install the fuel hose (fuel tank to fuel hose joint)
7. Fuel hose joint with its white paint mark facing downward.
8. Fuel outlet hose T. To the pressure regulator
9. Fuel pump U. Install the air vent hose (fuel hose joint to fuel tank)
with its white paint mark facing downward.
10. Sub-fuel tank
V. For California only
11. Fuel hose (fuel hose joint to fuel pump)
W. To the fuel tank
12. Fuel return pipe
X. To the intake manifold assembly
13. Fuel return hose (pressure regulator to fuel return
pipe) Y. Fasten the canister purge hose and fuel tank
breather/overflow hose with the holder. Align the
14. Pressure regulator paint mark on the fuel tank breather/overflow hose
15. Rollover valve 1 with the holder.
16. Rollover valve 2 Z. Fasten the canister purge hose and throttle cable
17. Cylinder-#2 left spark plug lead guide with the holder.
18. Rollover valve hose 1
20. Starter motor lead
21. Fuel tank breather/overflow hose
24. Air vent hose (fuel pump to fuel hose joint)
25. Fuel pump coupler
26. Canister purge hose (for California only)
28. Canister breather hose (for California only)
A. Install the fuel return hose (fuel return pipe to sub-
fuel tank) with its white paint mark facing upward.
B. Position the hose clamp over the white paint mark
on the hose, making sure not to install it on the
raised portion of the hose fitting. Point the ends of
the hose clamp upward.
C. Face the crimped section of the hose clamp
downward. Position the projections on the hose
clamp as shown in the illustration.
D. 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.
E. White paint mark
F. Align the ends of the hose clamp with the white
paint mark on the fuel return pipe.
G. Align the paint marks on the hoses with the hose
joint as shown in the illustration.
H. Fasten the fuel tank breather/overflow hose to the
throttle cable guide with the holder.
I. Align the paint mark on the hose with the hose joint
as shown in the illustration.
J. Fasten the fuel tank breather/overflow hose and
starter motor lead with the holder.
K. To the fuel injector
L. 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.
M. Face the crimped section of the hose clamp to the
left.
N. Point the ends of the hose clamp forward.
O. Install the air vent hose (fuel pump to fuel hose
joint) with its white paint mark facing upward.
P. Point the ends of the hose clamp upward.
2-62
A
5 8 9
C 10
4 7
3 6
D E
B
A
2
1
11
12
15
13
B
G
F
14 13 11
16
11 H
C
13 13
11 11
C
I
B C-C
4
5
A
K
17
7
19 D a b
D-D
18
L
D J
20
2-63
1. Intake air pressure sensor

2. Intake air pressure sensor hose
3. Air filter case breather hose 1
4. Fuel hose (intake manifold assembly to pressure
regulator)
5. Pressure regulator
8. ISC (idle speed control) unit inlet hose
10. Fuel tank breather/overflow hose (for California
only)
11. Cylinder-#2 ISC (idle speed control) unit outlet
hose
hose
14. Fuel outlet hose
15. Cylinder head breather hose
16. Hose joint cover
17. Throttle position sensor coupler
18. Cylinder-#1 injector coupler
19. Engine temperature sensor coupler
20. Sub-wire harness 2
A. Point the ends of the hose clamp to the left, angled
45° rearward.
B. Install the intake air pressure sensor hose up to the
bend in the hose fitting on the throttle body. Face
the white paint mark on the hose upward. Point the
ends of the hose clamp forward.
C. Fasten the canister purge hose and air filter case
breather hose 2 with the hose clamp. Point the
ends of the hose clamp upward. (For California
only)
D. Point 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 canister purge hose up to the bend in the
hose fitting on the throttle body. Face the white
paint mark on the hose upward. Point the ends of
the hose clamp upward. (For California only)
G. Point the ends of the hose clamp rearward, angled
to the left.
H. Align the white paint marks.
I. Align the yellow paint marks.
J. Fasten the sub-wire harness 2 with a plastic locking
tie, and then cut off the excess end of the tie.
K. Make sure that the total of distances “a” and “b”
shown in the illustration between the buckle of the
plastic locking tie and the ends of the rubber tube is
5 mm (0.20 in) or less.
L. Route the canister purge hose over the air filter
case joint clamp screw.
2-64
1
A
2
3
14
D 13 7 8 A 9 A
8
7 6
12 B
5
C
4
11 10
15
7
2
G
16
8
17
H
B
6
I
6 F
8 7
B A E
2-65

2. ISC (idle speed control) unit coupler
4. Rollover valve 1
5. Rollover valve 2
hose
hose
9. Hose joint
12. Throttle body assembly
15. Cylinder-#2 left ignition coil
16. Cylinder-#2 right ignition coil
A. Point the ends of the hose clamps outward.
B. Install the cylinder-#2 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold assembly)
completely onto the intake manifold. Face the green
paint mark on the hose to the left. Point the ends of
the hose clamp outward, angled 45° forward.
C. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold assembly)
completely onto the intake manifold. Face the blue
paint mark on the hose to the left.
D. Point the ends of the hose clamp upward.
E. Position the sub-wire harness 4 coupler on top of
the guide.
F. To the wire harness
G. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose onto the hose fitting of the ISC unit.
Align the blue paint mark on the hose with the blue
paint mark on the hose fitting.
H. Install the ISC (idle speed control) unit inlet hose
onto the hose fitting of the ISC unit. Align the white
paint mark on the hose with the white paint mark on
the hose fitting.
I. Install the cylinder-#2 ISC (idle speed control) unit
outlet hose onto the hose fitting of the ISC unit.
Align the green paint mark on the hose with the
green paint mark on the hose fitting.
2-66
CABLE ROUTING (for XV19CS(C)/ XV19C(C))
EAS1D77001
3
2
H
E G
1
G A 4
E
A B-B C-C D
2 3
C
5 6
3
B
I E-E F-F
B
5
A C 6
1 4 C
C
A B D
6 1 F
D
5
4
4
E
F
7
10
E 8
2-67
1. Clutch hose
4. Front brake hose
5. Throttle cable (decelerator cable)
6. Throttle cable (accelerator cable)
7. Horn 1 lead
8. Horn 1
9. Rear brake light switch lead
A. Pass the left handlebar switch lead through the
grommet.
B. 5–15 mm (0.20–0.59 in); except for XV19C(C)
(1US model)
C. Except for XV19C(C) (1US model)
D. Cross the throttle cables at the location shown in
the illustration.
E. Fasten the rear brake light switch lead with a
plastic locking tie. Point the end of the plastic
locking tie inward, and then cut off the excess end
of the tie.
F. Fasten the rear brake light switch lead with a
plastic locking tie. Point the end of the plastic
locking tie downward, and then cut off the excess
end of the tie.
G. 15–35°
H. Pass the right handlebar switch lead through the
cutouts in the lead holder.
I. Do not pinch the right handlebar switch lead.
2-68
B B
A 2
3
1
7
A
E
D
C
5 4
A
C
G
F
H 7 1
D 8
F F
9
L
10 F
F
E
M
K
H
J I E
11
C
7
7 O
D 3 N E-E F-F
2-69
1. Front right turn signal/position light lead

2. Wire harness
3. Main switch lead
4. Accessory light coupler
5. Joint coupler
6. Air temperature sensor lead
7. Front left turn signal/position light lead
9. Main switch
A. Position the main switch coupler in the rear of the
headlight housing.
B. Fasten the wire harness at the white tape with the
holder.
C. Position the accessory light coupler and joint
coupler in front of the plate.
D. Fasten the main switch lead with the holder.
E. Fasten the front left turn signal/position light lead,
front right turn signal/position light lead, and joint
coupler lead with the holder.
F. Fit the right handlebar switch lead in between the
grommet and the main switch cover bracket,
making sure to push the lead all the way down.
G. Route the main switch lead under the headlight
bracket.
H. Pass the left and right handlebar switch leads
through the cutouts in the main switch cover.
I. Pass the left and right handlebar switch leads
between the cable guide and the upper bracket.
J. Fit the left handlebar switch lead in between the
grommet and the main switch cover bracket,
making sure to push the lead all the way down.
K. Fit the right handlebar switch lead in between the
main switch and the cable guide, making sure to
push the lead all the way in.
L. Route the right handlebar switch lead along the
grommet.
M. Pass the front left turn signal/position light lead
through the lead guide.
N. Route the main switch lead behind the plate.
O. Bend the projection on the lead guide to fasten the
front right turn signal/position light lead.
2-70
T
2 U V
1 W
S
R
Q X
S
Q 3 Y
21 3 23
4 22
4
A-A B-B C-C
Z
9 10 11 D
F
12
7 8
6 C D E D
H
B G
G
A 1 2 3 4 5 C
B
H
C
A B
I
J
A 13
D 14
21 L K
P
M
E E
20 H G 15
O F
G
F
N 19 18 N 17 N 16
AA
16 16 16 16
H G-G F-F E-E
2-71
1. EXUP servo motor R. Face the buckle of the plastic locking tie upward
2. Fuse box with the end pointing outward. Cut off the excess
end of the plastic locking tie.
3. Wire harness
S. Inside of frame
4. Fuel outlet hose
T. Fasten the fuel outlet hose and wire harness to the
5. Cylinder-#1 right spark plug cap frame with a plastic locking tie as shown in the
6. Cylinder-#1 right ignition coil illustration. When installing the plastic locking tie,
7. Fuel sender (fuel tank) coupler insert the end of the tie through the lower opening
in the buckle of the tie, and then insert the end
8. Meter assembly coupler through the upper opening.
9. Throttle cable (accelerator cable) U. Make sure that the buckle of the plastic locking tie
10. Throttle cable (decelerator cable) does not protrude to the outside of the line shown
11. Front brake hose in the illustration.
12. Front turn signal/position light lead V. Point the end of the plastic locking tie outward,
angled downward, as shown in the illustration. Cut
13. Cylinder-#2 right spark plug cap off the excess end of the plastic locking tie. Make
14. Cylinder-#2 right ignition coil sure that the cut end of the plastic locking tie does
15. Rear brake light switch not contact the engine.
16. Clutch pipe W. Fasten the cylinder-#1 left and right ignition coil
leads and wire harness to the guide on the engine
17. Neutral switch lead bracket (right upper side) with a plastic locking tie.
18. Stator coil lead Be sure to position the leads and wire harness to
19. Speed sensor lead the inside of the guide. Cut off the excess end of
20. EXUP cable
X. Fasten the cylinder-#1 left and right ignition coil
21. O2 sensor lead leads and sub-wire harness 2 to the guide on the
22. Cylinder-#1 right spark plug lead engine bracket (right upper side) with a plastic
locking tie. Be sure to position the leads and sub-
23. Sub-wire harness 2 coupler wire harness to the inside of the guide. Align the
A. Fasten the sub-wire harness with the holder. plastic locking tie with the purple tape on sub-wire
B. Fasten the cylinder-#1 right spark plug lead, fuel harness 2. Cut off the excess end of the plastic
outlet hose, wire harness, and fuel tank damper locking tie.
with a plastic locking tie. Install the plastic locking Y. To the fuel injectors, engine temperature sensor,
tie in the middle slot of the fuel tank damper. and throttle position sensor
C. Fasten the wire harness to the right ignition coil Z. To the ignition coil
bracket with a plastic locking tie. Cut off the excess AA.Install the clutch pipe onto the clutch release
end of the plastic locking tie. cylinder, making sure that the pipe contacts the
D. Fasten the wire harness and meter assembly lead projection on the cylinder.
to the frame with a plastic locking tie. Point the end
of the plastic locking tie inward. Do not cut off the
excess end of the plastic locking tie.
E. Position the plastic locking tie to the front of the
projection on the frame.
F. Align the positioning tape on the wire harness with
the top of the frame.
G. 5–15 mm (0.20–0.59 in)
H. Fasten the front turn signal/position light leads to
the front brake hose with a plastic locking tie.
Position the buckle of the plastic locking tie to the
outside of the front brake hose, with the end of the
tie pointing outward, and then cut off the excess
end of the tie.
I. Pass the wire harness through the guide.
J. Fasten the wire harness and cylinder-#2 right
spark plug lead with a plastic locking tie. Point the
end of the plastic locking tie downward, and then
cut off the excess end of the tie.
K. Connect the ignition coil lead with the “2” mark to
the cylinder-#2 right ignition coil.
L. To the neutral switch
M. To the speed sensor
N. Fasten the stator coil lead with a plastic locking tie.
Point the end of the plastic locking tie outward, and
O. To the brake fluid reservoir
P. Pass the O2 sensor lead through the cutout in the
heat protector.
Q. Outside of frame
2-72
3 22 AB 23 25 AE AG 29
AC AD 2 AD AC AD AH
1 23 26
3
2 24 AF
27 28 19
A-A B-B C-C D-D E-E F-F
A
A B C
A 2 3 4 5 4 5
B E
D
C 6 7 F G 8 H
B E
D
C
D E
AA
I
Z F F
21 G
20
Y 9
X 10
22
19 J
W 11
I K
V L
18 T
I H
U 17 S R Q 16 Q P 15 14 O 13 12 N M
30 31 32 33 34 35
AM
AO
AP J 36
38
28 AI AI AJ
37 J
17 37 19 17
I AN AL AK
U
S I R I-I H G
2-73
1. Clutch hose H. Route sub-wire harness 1 to the inside of the

2. Throttle cable (accelerator cable) frame.
3. Throttle cable (decelerator cable) I. To the tail/brake light
4. Right handlebar switch coupler J. Fasten the starter motor lead, horn 1 lead, rear
brake light switch lead, sidestand switch lead,
5. Left handlebar switch coupler crankshaft position sensor lead, and
6. Cylinder-#1 left ignition coil rectifier/regulator lead to the frame with a plastic
7. Cylinder-#1 left spark plug cap locking tie.
8. Sub-wire harness 1 K. Make sure that there is no slack in the stator coil
lead and rectifier/regulator lead in the area shown
9. Rectifier/regulator in the illustration.
10. Crankshaft position sensor lead L. Fasten the stator coil lead with a plastic locking tie.
11. Stator coil lead Point the end of the plastic locking tie outward, and
12. Rectifier/regulator lead then cut off the excess end of the tie.
13. Lean angle sensor M. Fasten the stator coil lead and rectifier/regulator
lead with a plastic locking tie. Point the end of the
14. Horn 2 lead plastic locking tie outward, and then cut off the
15. Horn 2 excess end of the tie.
16. Sidestand switch N. Fasten the stator coil lead and rectifier/regulator
17. Rear brake light switch lead lead with a plastic locking tie. Align the white tape
on the rectifier/regulator lead with the plastic
18. Horn 1 locking tie. Point the end of the plastic locking tie
19. Starter motor lead outward, and then cut off the excess end of the tie.
20. Cylinder-#2 left spark plug cap O. Fasten the lean angle sensor lead, starter motor
21. Cylinder-#2 left ignition coil lead, horn 1 lead, rear brake light switch lead, and
sidestand switch lead with the holder.
22. Front brake hose
P. Route the starter motor lead, horn 1 lead, rear
23. Left and right handlebar switch leads brake light switch lead, and sidestand switch lead
24. Cylinder-#2 left spark plug lead to the inside of the frame boss.
25. Fuel tank breather hose Q. Fasten the starter motor lead, horn 1 lead, rear
26. Cylinder-#1 left spark plug lead brake light switch lead, and sidestand switch lead
with a plastic locking tie. Point the end of the plastic
27. Cylinder-#1 left ignition coil lead locking tie outward, and then cut off the excess end
28. Wire harness of the tie.
29. Speed sensor lead R. Fasten the starter motor lead, horn 1 lead, and
30. Main fuse rear brake light switch lead with a plastic locking
tie. Point the end of the plastic locking tie outward.
31. Turn signal relay Be sure to install the plastic locking tie behind the
32. Relay unit frame cross member and to fasten the rear brake
33. Headlight relay light switch lead at the white tape.
34. Starter relay S. Align the positioning tape on the starter motor lead
with the engine mounting bolt (front lower side).
35. EXUP servo motor
T. Route the starter motor lead, horn 1 lead, and rear
36. EXUP cable brake light switch lead along the frame in the area
37. Horn 1 lead shown in the illustration, making sure not to cross
38. Canister (for California only) the leads.
A. Fasten the left and right handlebar switch leads, U. Fasten the starter motor lead, horn 1 lead, and
and cylinder-#2 left spark plug lead to the frame rear brake light switch lead with a plastic locking
with a plastic locking tie. Position the plastic locking tie. Point the end of the plastic locking tie inward.
tie to the front of the projection on the frame. Point V. Fasten the horn 1 lead, rear brake light switch
the end of the plastic locking tie inward. Do not cut lead, and starter motor lead with a plastic locking
off the excess end of the plastic locking tie. tie. Point the end of the plastic locking tie inward,
B. Fasten the left and right handlebar switch leads to and then cut off the excess end of the tie.
the frame with a plastic locking tie. Point the end of W. Route the horn 1 lead to the rear of the starter
the plastic locking tie inward. Do not cut off the motor lead.
excess end of the plastic locking tie. X. Fasten the ignition coil lead at the white tape with
C. Fasten the left and right handlebar switch leads the holder.
with the holder. Y. Connect the ignition coil lead with the “2” mark to
D. 30–40 mm (1.18–1.57 in) the cylinder-#2 left ignition coil.
E. Fasten the cylinder-#1 left ignition coil lead and Z. Fasten the throttle cable (accelerator cable) and
cylinder-#1 left spark plug lead with a plastic fuel tank breather hose with the holder.
inward, and then cut off the excess end of the tie.
F. Fasten the crankshaft position sensor lead, neutral
switch lead, and sidestand switch lead with the
holders.
G. Fasten the starter motor lead, speed sensor lead,
and wire harness with the holders.
2-74
3 22 AB 23 25 AE AG 29
AC AD 2 AD AC AD AH
1 23 26
3
2 24 AF
27 28 19
A-A B-B C-C D-D E-E F-F
A
A B C
A 2 3 4 5 4 5
B E
D
C 6 7 F G 8 H
B E
D
C
D E
AA
I
Z F F
21 G
20
Y 9
X 10
22
19 J
W 11
I K
V L
18 T
I H
U 17 S R Q 16 Q P 15 14 O 13 12 N M
30 31 32 33 34 35
AM
AO
AP J 36
38
28 AI AI AJ
37 J
17 37 19 17
I AN AL AK
U
S I R I-I H G
2-75
AA.Fasten the throttle cable (accelerator cable),

throttle cable (decelerator cable), and fuel tank
breather hose with the holder. Align the white paint
mark on the throttle cable (decelerator cable) with
the holder.
AB.Fasten the left and right handlebar switch leads at
the positioning tape on each lead to the fuel tank
bracket with a plastic locking tie. Point the end of
the plastic locking tie inward.
AC.Inside of frame
AD.Outside of frame
AE.Align the holder with the bend in the fuel tank
breather hose.
AF. Be sure to turn the portion of the holder that has
the larger diameter so that the stopper is facing
forward.
AG.Face the buckle of the plastic locking tie inward.
AH.Forward
AI. Pass a plastic locking tie through the hole in the
battery box projection, and then fasten the wire
harness with the tie.
AJ. Pass a plastic locking tie through the hole in the
rubber plate, and then fasten the wire harness with
the tie.
AK.Fasten the stator coil lead at the white tape with a
plastic locking tie.
AL. Fasten the stator coil lead with a plastic locking tie.
AM.Route the wire harness along the side of the fuse
box/starter relay bracket.
AN.Install the lead cover, making sure not to pinch the
stator coil lead and rectifier/regulator lead.
AO.For California only
AP. Route the horn 1 lead to the rear of the canister.
2-76
15 3
14
16
22
A
17
B 21
18
1 20 19
7
13
12 A-A
2
13
20 17 3
12 C
D
11
L 14
K 19
7 B-B
D
D
M
3
J 24 N
C E
23
C-C
I
A C A 25
N
H B B F
4
M O
10 5
D-D
6
9 G 8 7
P 7
V T
28
W
X 4 Q
U
U 27
26 S 8 R
2-77
1. Meter assembly coupler O. Position the buckle of the plastic band below the
2. Fuel sender (fuel tank) coupler top of the projection on the frame.
3. Wire harness P. View with tray removed
4. Negative battery lead Q. Route the negative battery lead under the starter
motor lead and positive battery lead.
5. EXUP servo motor lead
R. Route the positive battery lead (main fuse to
6. Fuse box starter relay) over the tray.
7. Starter motor lead S. Route the positive battery lead (battery to starter
8. Positive battery lead relay) under the tray.
9. Sub-wire harness 1 T. View with tray installed
10. ECU (engine control unit) U. To the tail/brake light
11. Intake air pressure sensor coupler V. View with ECU removed
12. Left handlebar switch lead W. Wrap the protective covering around the couplers
13. Right handlebar switch lead (crankshaft position sensor coupler, auxiliary DC
jack coupler, neutral switch coupler, sub-wire
14. Neutral switch lead harness 1 coupler, speed sensor coupler,
15. Fuel outlet hose sidestand switch coupler, and joint coupler).
16. Frame X. When installing the ECU, be sure not to pinch the
17. Crankshaft position sensor lead leads in the areas shown in the illustration with
oblique lines.
18. Oil tank
19. Speed sensor lead
20. Sidestand switch lead
21. Sub-fuel tank
25. Cylinder-#1 left ignition coil lead
26. Battery
27. Main fuse
28. Fuel pump lead
A. Route the meter assembly lead and fuel sender
(fuel tank) lead to the front of the projection on the
Air filter case.
B. Route the meter assembly lead and fuel sender
(fuel tank) lead to the outside of the guide on the
fuel tank bracket.
C. Position the 4-pin white coupler, 2-pin white
coupler, 4-pin green coupler, and 4-pin black
coupler in the order listed from front to rear.
D. Position the 3-pin black coupler, 3-pin gray coupler,
and 3-pin yellow coupler in the order listed from
front to rear.
E. Fasten the wire harness at the white tape with the
plastic band. Align the plastic band with the rib on
the tray. Point the end of the plastic band inward.
F. Route the crankshaft position sensor lead,
sidestand switch lead, neutral switch lead, starter
motor lead, and speed sensor lead under the fuel
outlet hose.
G. Point the end of the plastic band inward.
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 band. The end of the
plastic band should be under the fuel hose joint,
pointing inward.
J. Route the intake air pressure sensor lead so that it
does not protrude past the top of the frame.
K. Fasten the cylinder-#1 left ignition coil lead with the
plastic band. Align the plastic band with the
characters on the frame.
L. Align the tape on the cylinder-#1 left ignition coil
lead with the plastic band.
M. Outside of frame
N. Inside of frame
2-78
1
A
B
A
B
A
E
1 1
F
C
4
B
C
C D
F E D
D
D D
3 G
1
I
1
H
F E D-D
C
2-79
1. Brake fluid reservoir hose

3. Rear brake hose
4. EXUP cable
A. Install the brake fluid reservoir hose with its white
paint mark facing upward.
B. Point the ends of the hose clamp forward.
C. Position the plastic locking tie 10–15 mm (0.39–
0.59 in) from the end of the protector. Face the
buckle of the plastic locking tie upward. Cut off the
excess end of the plastic locking tie to 10 mm (0.39
in) or less.
D. Align the end of the protector with the end of the
pipe section of the rear brake hose.
E. Align the paint mark on the brake fluid reservoir
hose with the paint mark on the brake hose joint.
F. To the rear brake caliper
G. To the brake fluid reservoir
H. Install the holder as shown in the illustration.
I. Route the brake fluid reservoir hose through the
passage in the protector, wrap the protector
around the rear brake hose, and then fasten the
protector with the plastic locking tie.
2-80
1
2
3
4
E
5
6
A A
7
D 8
B B 11 C
9
12
E 10
I F
11 B F
13 A
15
A-A G
H H
14
12
13
C
C 3 7 L M 16
B-B J
T
14 K B
N
S
C-C 17
5
U X R
V W 4
Q
P E
O
5 3
6
4
18
6
10
7
16
18
D
18
D
D-D F
19
2-81
1. Fuel tank breather hose

2. Fuel tank
3. Air vent hose (fuel hose joint to fuel tank)
6. Fuel hose joint
7. Fuel outlet hose
8. Fuel pump
9. Sub-fuel tank
10. Fuel hose (fuel pump to fuel hose joint)
11. Fuel return pipe
12. Rollover valve 2
13. Rollover valve 1
14. Fuel tank breather/overflow pipe
17. Fuel pump coupler
19. Canister breather hose (for California only)
A. Install the fuel return hose (fuel return pipe to sub-
fuel tank) with its white paint mark facing upward.
B. Position the hose clamp over the white paint mark
on the hose, making sure not to install it on the
raised portion of the pipe.
C. Face the fastener of the clamp downward, making
sure that the projections on the clamp are
positioned as shown in the illustration.
D. 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.
E. Make sure that the rollover valve holder is not
resting on top of the stopper.
F. Point the ends of the hose clamp outward.
G. Install the fuel return hose onto the fuel return pipe
until the hose contacts the white paint mark on the
pipe.
H. Align the ends of the hose clamps with the white
paint marks on the fuel return hose.
I. Install the rollover valve hoses with their paint
marks facing outward.
J. Point the ends of the hose clamp inward.
K. To the fuel injector
L. Align the clamp with the yellow paint mark, making
sure to face the fastener of the clamp to the left.
M. Point 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. Point the ends of the hose clamp upward.
P. Face the fastener of the clamp to the left.
Q. Face the fastener of the clamp to the left. The
projections on the clamp may be facing in any
direction.
R. Install the fuel hose (fuel tank to fuel hose joint)
S. To the pressure regulator
T. Install the air vent hose (fuel hose joint to fuel tank)
U. For California only
V. Make sure that the canister hose is not twisted.
W. To the fuel tank
X. To the rollover valve
2-82
A
4 5
6
3 7 C
B 8 9
A C 10
2
1
B
13 D
11
E 12 11 9
9 G 14
11 C 11
9 9
C
H
B C-C
5
4
A J
15
6 D
18 a b
D-D
16
K
D I
17
2-83

4. Fuel hose (intake manifold assembly to pressure
regulator)
hose
hose
12. Fuel outlet hose
14. Hose joint cover
15. Throttle position sensor coupler
16. Cylinder-#1 injector coupler
18. Engine temperature sensor coupler
A. Face the ends of the hose clamp to the left, angled
45° rearward.
B. Install the 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. Point the ends of the hose clamp
forward.
C. Point the ends of the hose clamp to the left.
D. Point the ends of the hose clamp to the right.
E. Install the canister purge hose onto the throttle
body pipe up to the bend in the pipe, making sure
to face the yellow paint mark on the hose upward.
Point the ends of the hose clamp upward. (for
California only)
F. Point the ends of the hose clamp rearward, angled
to the left.
G. Align the white paint marks.
H. Align the yellow paint marks.
I. Fasten the sub-wire harness 2 with a plastic
locking tie, and then cut off the excess end of the
tie.
J. Make sure that the total of distances “a” and “b”
shown in the illustration between the buckle of the
plastic locking tie and the ends of the rubber tube
is 5 mm (0.20 in) or less.
K. Route the canister purge hose over the air filter
case joint clamp screw. (for California only)
2-84
A 2
3
A
1
B A
7 6
B
12 5 4
11 6
E
C
8
10
B
6
I
G
4
I 4
5
6 F
B A
2-85

2. ISC (idle speed control) unit coupler
hose
hose
7. Hose joint
A. Point the ends of the hose clamp upward.
B. Point 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 pink paint mark on the
hose to the left. Point the ends of the hose clamp
outward, angled 45° forward.
D. To the canister (for California only)
E. Install the cylinder-#1 ISC (idle speed control) unit
outlet hose (hose joint to intake manifold
assembly) completely onto the intake manifold,
making sure to face the red paint mark on the hose
to the left.
F. 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.
G. 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.
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. 60°
2-86
2-87
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

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

CHECKING AND CHARGING THE BATTERY....................................... 3-33
CHECKING THE FUSES ........................................................................3-33
REPLACING THE HEADLIGHT BULBS
(for XV19S(C)/ XV19CTS(C)) .................................................................3-33
REPLACING THE HEADLIGHT BULB (for XV19CS(C)/ XV19C(C))...... 3-34
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-35
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAU17601
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
(13000 km) or 12 months.
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
INITIAL ODOMETER READINGS

8000 mi 12000 mi 16000 mi 20000 mi
600 mi 4000 mi (13000 (19000 (25000 (31000
No. ITEM ROUTINE (1000 km) (7000 km)
or or km) km) km) km)
or or or or
1 month 6 months 12 months 18 months 24 months 30 months
• Check fuel hoses for cracks or

1 * Fuel line damage. √ √ √ √ √
• Replace if necessary.
• Check condition.
• Adjust gap and clean.
2 * Spark plugs √ Replace. √ Replace. √
• Replace every 8000 mi
• Check and adjust valve clear-
3 * Valve clearance ance when engine is cold. Every 16000 mi (25000 km)
• Adjust if necessary.
• Check breather hose for
Crankcase
4 * breather system cracks or damage. √ √ √ √ √
5 * Fuel injection • Adjust synchronization. √ √ √ √ √ √
• Check for leakage.
• Tighten if necessary.
6 * Exhaust system √ √ √ √ √
• Replace gasket(s) if neces-
sary.
Evaporative emis-
• Check control system for
7 * sion control sys- damage. √ √
tem (for California
only) • Replace if necessary.
EAU32188
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi
• Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer
perform the service.
3-1

8000 mi 12000 mi 16000 mi 20000 mi
600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
12 months 18 months 24 months 30 months
1 * Air filter element • Replace. Every 24000 mi (37000 km)
• Check operation and fluid
2 * Clutch leakage. √ √ √ √ √ √
• Correct if necessary.
• Check operation, fluid level,
and for fluid leakage.
3 * Front brake • Replace brake pads if neces- √ √ √ √ √ √
sary.
• Check operation, fluid level,
and for fluid leakage.
4 * Rear brake √ √ √ √ √ √
• Replace brake pads if neces-
sary.
• Check for cracks or damage.
• Check for correct routing and √ √ √ √ √
5 * Brake hoses clamping.
• Replace. Every 4 years
6 * Brake fluid • Replace. Every 2 years
• Check runout and for dam-
7 * Wheels age. √ √ √ √ √
• Check tread depth and for
damage.
8 * Tires • Replace if necessary. √ √ √ √ √
• Check air pressure.
• Check bearings for smooth
9 * Wheel bearings operation. √ √ √ √ √
10 * Swingarm pivot • Check bearing assemblies for √ √ √ √ √
bearings looseness.
• Check belt condition.
• Replace if damaged.
11 * Drive belt • Check belt tension. √ Every 2500 mi (4000 km)
• Adjust if necessary.
• Check bearing assemblies for
looseness. √ √ √ √ √ √
12 * Steering bearings
• Moderately repack with lithi- Every 16000 mi (25000 km)
um-soap-based grease.
• Check all chassis fitting and
13 * Chassis fasteners fasteners. √ √ √ √ √
Brake lever pivot
14 • Apply silicone grease lightly. √ √ √ √ √
shaft
Brake pedal pivot • Apply lithium-soap-based
15 shaft grease lightly. √ √ √ √ √
16 Clutch lever pivot • Apply silicone grease lightly. √ √ √ √ √

shaft
Shift pedal pivot • Apply lithium-soap-based
17 √ √ √ √ √
shaft grease lightly.
• Check operation.
18 Sidestand pivot • Apply lithium-soap-based √ √ √ √ √
grease lightly.
• Check operation and replace
19 * Sidestand switch if necessary. √ √ √ √ √ √
• Check operation and for oil
20 * Front fork leakage. √ √ √ √ √
Shock absorber • Check operation and for oil
21 * leakage. √ √ √ √ √
assembly • Replace if necessary.
22 * Rear suspension • Apply lithium-soap-based √
link pivots grease lightly.
• Change (warm engine before
23 Engine oil √ √ √ √ √ √
draining).
Engine oil filter
24 * cartridge • Replace. √ √ √
3-2

8000 mi 12000 mi 16000 mi 20000 mi
600 mi 4000 mi
No. ITEM ROUTINE (1000 km) (7000 km) (13000 (19000 (25000 (31000
km) km) km) km)
or or or or or or
1 month 6 months
12 months 18 months 24 months 30 months
• Check for leakage.
• Change at initial 600 mi (1000
25 * Transfer case oil km) or 1 month, and thereaf- Change. √ Change.
ter every 16000 mi (25000
km) or 24 months.
Front and rear
26 * brake switches • Check operation. √ √ √ √ √ √
• Apply Yamaha chain and ca-
27 * Control cables ble lube or engine oil thor- √ √ √ √ √ √
oughly.
• Check operation.
• Check throttle grip free play,
28 * Throttle grip and adjust if necessary. √ √ √ √ √
• Lubricate cable and grip
housing.
Lights, signals • Check operation.
29 * √ √ √ √ √ √
and switches • Adjust headlight beam.
EAU38440
TIP
• Air filter
• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be
cleaned with compressed air to avoid damaging it.
• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
• Hydraulic brake and clutch systems
• After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder,
always change the fluid. Regularly check the brake and clutch fluid levels and fill the reservoirs as
required.
• Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and
clutch release cylinder every two years.
• Replace the brake and clutch hoses every four years or if cracked or damaged.
3-3
ENGINE
EAS20470
• Fuel tank
ENGINE Refer to “FUEL TANK” on page 6-1.
EAS20530
• Air filter case
ADJUSTING THE VALVE CLEARANCE Refer to “GENERAL CHASSIS” on page 4-1.
The following procedure applies to all of the • Muffler
valves. • Exhaust pipes
TIP Refer to “ENGINE REMOVAL” on page 5-1.
2. Disconnect:
• The valve clearance is automatically adjusted
• Spark plug caps
by the hydraulic valve lifter. However, there are
3. Remove:
times when the valve clearance needs to be
• Spark plugs
adjusted manually. If this is the case, adjust the
4. Remove: (for XV19S(C)/ XV19CTS(C))
clearance of the two maladjusted or worn
• Shift pedal assembly “1”
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.
1
5. Remove:
• Damper cover “1”
• Damper “2”
• Timing mark accessing screw “3”
• Crankshaft end screw “4”
If clearance is on the adjusting screw “2” side, 4

tighten the adjusting screw and bring the valve
clearance “b” within specification.
3 2
1
6. Remove:
• Camshaft sprocket cover “1”
• Valve clearance adjustment should be made

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

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

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

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

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

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

moving and tighten the locknut to specifica-
tion.
Locknut (rocker arm adjusting 4. Disconnect:

screw) • Intake air pressure sensor hose “1”
T.
R.
20 Nm (2.0 m·kg, 14 ft·lb) • Cap “2”
Tappet adjusting tool (4 mm)

90890-04133
2
YM-A5970
e. Measure the valve clearance again. 1

f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained. 5. Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Hose “1” (Parts No.: 5JW-24311-00)
13.Install: • 3-way joint “2” (Parts No.: 90413-05014)
• All removed parts • Vacuum gauge hose for #1 “3”
Refer to “CAMSHAFTS” on page 5-17. • Vacuum gauge hose for #2 “4”
TIP • Intake air pressure sensor hose “5”
For installation, reverse the removal procedure. • Vacuum gauge
• Tachometer
EAS20570
SYNCHRONIZING THE THROTTLE BODIES Vacuum gauge

90890-03094
TIP Vacuummate
Prior to synchronizing the throttle bodies, the YU-44456
valve clearance and the engine idling speed
should be properly adjusted and the ignition tim-
ing should be checked. 4
1. Stand the vehicle on a level surface.
TIP
Place the vehicle on a suitable stand.
1
2. Remove:
• Rider seat 5
• Rider seat bracket assembly 3 2
Refer to “GENERAL CHASSIS” on page 4-1.
• Cylinder-#1 ignition coil cover
Refer to “ENGINE REMOVAL” on page 5-1.
3-7
ENGINE
6. Install: 8. Stop the engine and remove the measuring

• Fuel tank equipment.
Refer to “FUEL TANK” on page 6-1. 9. Adjust:
7. Adjust: • Throttle cable free play
• Throttle body synchronization Refer to “ADJUSTING THE THROTTLE CA-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ BLE FREE PLAY” on page 3-8.
a. Start the engine and let it warm up for several
minutes, and then let it run at specified en- Throttle cable free play
gine idling speed. 4.0–6.0 mm (0.16–0.24 in)
Engine idling speed 10.Install:

850–950 r/min • Fuel tank
b. With throttle body #1 as standard, adjust • Cylinder-#1 ignition coil cover
throttle body #2 using the air screw “1” (for Refer to “ENGINE REMOVAL” on page 5-1.
throttle body #2). • Rider seat bracket assembly
• Rider seat
1
EAS20630
ADJUSTING THE THROTTLE CABLE FREE

PLAY
TIP
Prior to adjusting the throttle cable free play, the
engine idling speed and throttle body synchroni-
zation should be adjusted properly.
TIP 1. Check:
• After each step, rev the engine two or three • Throttle cable free play “a”
times, each time for less than a second, and Out of specification → Adjust.
check the synchronization again.
• If the air screw was removed, turn the screw
3/4 turn in and be sure to synchronize the throt-
tle body.
ECA14900
NOTICE
a
Do not use the throttle valve adjusting
screws to adjust the throttle body synchroni-
zation.
Intake vacuum Throttle cable free play

26.6–30.6 kPa (7.9–9.0 inHg) 4.0–6.0 mm (0.16–0.24 in)
(200–230 mmHg)
2. Adjust:
TIP • Throttle cable free play
The difference in vacuum pressure between two ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
throttle bodies should not exceed 1.33 kPa (10 a. Loosen the locknut “1”.
mmHg). b. Turn the adjusting nut “2” in direction “a” or “b”
until the specified throttle cable free play is
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ obtained.
3-8
ENGINE
4. Check:
Direction “a” • Spark plug type
Throttle cable free play is increased. Incorrect → Change.
Direction “b”
Throttle cable free play is decreased. Manufacturer/model
NGK/DPR8EA-9
c. Tighten the locknut “1”. Manufacturer/model
DENSO/X24EPR-U9
Locknut (throttle cable)
XV19C(C) (1US model): 5. Check:
T.
R.
3 Nm (0.3 m·kg, 2.2 ft·lb) • Electrode “1”

Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
2 6. Clean:
a
• Spark plug
A 1 2 (with a spark plug cleaner or wire brush)
a
b 7. Measure:
1
• Spark plug gap “a”
b (with a wire thickness gauge)
Out of specification → Regap.
A. For XV19C(C) (1US model)
EWA12910
Spark plug gap
WARNING 0.8–0.9 mm (0.031–0.035 in)
After adjusting the throttle cable free play,
start the engine and turn the handlebar to the
right and to the left to ensure that this does
not cause the engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS20680
CHECKING THE SPARK PLUGS

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

R.
• Air filter case

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

TIP
Prior to checking the ignition timing, check the
wiring connections of the entire ignition system. 1
Make sure all connections are tight and free of
corrosion.
1. Stand the vehicle on a level surface. 5. Check:
2. Remove: (for XV19S(C)/ XV19CTS(C)) • Ignition timing
• Shift pedal assembly “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
Engine idling speed

850–950 r/min
1 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
3. Remove: system.
• Damper cover “1”
• Damper “2”
a b
• Timing mark accessing screw “3”
3 2
TIP
1
The ignition timing is not adjustable.
4. Connect: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Timing light “1” 6. Install:
• Tachometer • Timing mark accessing screw
• Damper
Timing light
• Damper cover
90890-03141
YU-03141 Damper cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
7. Install: (for XV19S(C)/ XV19CTS(C))

Shift pedal bolt

18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
3-10
ENGINE
TIP
Recommended brand
Align the mark “a” on the shift pedal shaft with YAMALUBE
the slot in the shift pedal. Type
SAE 10W-30, 10W-40, 10W-50,
15W-40, 20W-40 or 20W-50
Recommended engine oil grade
API service SG type or higher,
1 JASO standard MA
0 10 30 50 70 90 110 130 ˚F
SAE 10W-30
a
SAE 10W-40
SAE 10W-50
EAS20750
SAE 15W-40
CHECKING THE ENGINE OIL LEVEL SAE 20W-40
1. Stand the vehicle on a level surface. SAE 20W-50
TIP –20 –10 0 10 20 30 40 50 ˚C
• Place the vehicle on a suitable stand.
ECA13380
• Make sure the vehicle is upright.
NOTICE
2. Start the engine, warm it up for approximately • Engine oil also lubricates the clutch and the
15 minutes until the oil temperature rises to wrong oil types or additives could cause
60 °C (140 °F), and then turn it off. clutch slippage. Therefore, do not add any
3. Remove: chemical additives.
• Rider seat • Do not allow foreign materials to enter the
Refer to “GENERAL CHASSIS” on page 4-1. crankcase.
4. Remove:
• Dipstick “1” 6. Start the engine, warm it up for several min-
5. Check: utes, and then turn it off.
• Engine oil level 7. Check the engine oil level again.
The engine oil level should be between the TIP
minimum level mark “a” and maximum level Before checking the engine oil level, wait a few
mark “b”. minutes until the oil has settled.
Below the minimum level mark → Add the
8. Install:
recommended engine oil to the proper level.
• Dipstick
TIP
9. Install:
• Before checking the engine oil level, wait a few • Rider seat
minutes until the oil has settled. Refer to “GENERAL CHASSIS” on page 4-1.
• Do not screw the dipstick in when inspecting
the oil level. EAS20780
CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-
b utes, and then turn it off.
2. Place a container under the engine oil drain
a bolts.
1 3. Remove:
• Engine oil filler cap “1”
3-11
ENGINE
4. Remove: b. Lubricate the O-ring “3” of the new oil filter

• Engine oil drain bolt (oil tank) “1” cartridge with a thin coat of engine oil.
ECA13390
(along with the gasket)
NOTICE
Make sure the O-ring “3” is positioned cor-
1 rectly in the groove of the oil filter cartridge.
5. Remove:
• Engine oil drain bolts (crankcase) “1”
(along with the gaskets)
c. Tighten the new oil filter cartridge to specifi-
cation with an oil filter wrench.
Oil filter cartridge

17 Nm (1.7 m·kg, 12 ft·lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Check:
• Engine oil drain bolt gaskets
1 1 Damage → Replace.
6. Drain: 9. Install:
• Engine oil • Engine oil drain bolt (oil tank)
(completely from the oil tank and crankcase) (along with the gasket)
7. If the oil filter cartridge is also to be replaced,
Engine oil drain bolt (oil tank)
perform the following procedure. 43 Nm (4.3 m·kg, 31 ft·lb)
T.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
R.
a. Remove the oil filter cartridge “1” with an oil

10.Install:
filter wrench “2”.
• Engine oil drain bolts (crankcase)
Oil filter wrench (along with the gaskets)
90890-01426
YU-38411 Engine oil drain bolt (crankcase)
32 Nm (3.2 m·kg, 23 ft·lb)
T.
R.
11.Fill:
• Oil tank
(with the specified amount of the recom-
mended engine oil)
3-12
ENGINE
Engine oil quantity

Quantity (disassembled)
5.20 L (5.50 US qt) (4.58 Imp.qt)
Without oil filter cartridge re-
placement
4.10 L (4.33 US qt) (3.61 Imp.qt)
With oil filter cartridge replace- 1
ment
4.90 L (5.18 US qt) (4.31 Imp.qt)
TIP b. Start the engine and keep it idling until engine

Pour the engine oil in two stages. First, pour in oil starts to seep from the oil gallery bolts. If
2.5 L of oil, then start the engine and rev it 3 to 5 no engine oil comes out after one minute, turn
times. Stop the engine, and then pour in the re- the engine off so that it will not seize.
mainder of the specified amount. c. Check the engine oil passages, the oil filter
EC1D71008
cartridge and the oil pump for damage or
NOTICE leakage. Refer to “OIL PUMP” on page
5-101.
When starting the engine make sure the dip- d. Start the engine after solving the problem(s)
stick is securely fitted into the oil tank. and check the engine oil pressure again.
12.Fill: (when engine is disassembled) e. Tighten the oil gallery bolts to specification.
• Crankcase and oil tank
(with the specified amount of the recom- Oil gallery bolt
mended engine oil) 8 Nm (0.8 m·kg, 5.8 ft·lb)
T.
R.
Engine oil quantity ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Quantity (disassembled) EAS20840
5.20 L (5.50 US qt) (4.58 Imp.qt) CHECKING THE TRANSFER GEAR OIL
Engine LEVEL
3.2 L (3.38 US qt) (2.82 Imp.qt) 1. Stand the vehicle on a level surface.
Oil tank TIP
2.0 L (2.11 US qt) (1.76 Imp.qt)
13.Install: • Make sure the vehicle is upright.
• Engine oil filler cap 2. Remove:
14.Start the engine, warm it up for several min- • Transfer gear oil check bolt “1”
utes, and then turn it off.
15.Check:
• Engine
(for engine oil leaks)
16.Check:
• Engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-11.
17.Check: 1
• Engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3. Check:
a. Slightly loosen the oil gallery bolts “1”.
• Transfer gear oil level
The transfer gear oil level should be up to the
brim “1” of the hole.
Below the brim → Add the recommended
transfer gear oil to the proper level.
3-13
ENGINE
6. Install:
• Transfer gear oil drain bolt
(along with the gasket)
1
Transfer gear oil drain bolt
18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
7. Fill:
• Transfer gear case
mended transfer gear oil)
Type
Quantity
SAE 80 API GL-4 Hypoid gear
0.55 L (0.58 US qt) (0.48 Imp.qt)
oil
Quantity (disassembled)
EC1D71024 0.60 L (0.63 US qt) (0.53 Imp.qt)
NOTICE
Do not allow foreign materials to enter the
transfer gear case.
4. Install:
• Transfer gear oil check bolt
Transfer gear oil check bolt

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

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

TIP
Place the vehicle on a suitable stand.
2. Check:
2 • Clutch fluid level
1
Below the minimum level mark “a” → Add the
4. Drain: recommended clutch fluid to the proper level.
• Transfer gear oil
Recommended clutch fluid
(completely from the transfer gear case)
Brake fluid DOT 4
5. Check:
• Transfer gear oil drain bolt gasket
Damage → Replace.
3-14
ENGINE
precaution could allow air to enter the hydraulic

clutch system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to let
the clutch fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.
1. Bleed:
• Hydraulic clutch system
EWA13370
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING
a. Add the recommended clutch fluid to the
proper level.
• Use only the designated clutch fluid. Other b. Install the clutch master cylinder reservoir di-
clutch fluids may cause the rubber seals to aphragm.
deteriorate, causing leakage and poor c. Connect a clear plastic hose “1” tightly to the
clutch performance. bleed screw “2”.
• Refill with the same type of clutch fluid that
is already in the system. Mixing clutch flu- 1
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance. 2
• When refilling, be careful that water does
not enter the clutch fluid reservoir. Water
will significantly lower the boiling point of
the clutch fluid and could cause vapor lock.
ECA13420
NOTICE
Clutch fluid may damage painted surfaces or d. Place the other end of the hose into a con-
plastic parts. Therefore, always clean up any tainer.
spilt clutch fluid immediately. e. Slowly squeeze the clutch lever several
TIP times.
f. Fully squeeze the clutch lever without releas-
In order to ensure a correct reading of the clutch
ing it.
fluid level, make sure the top of the reservoir is
g. Loosen the bleed screw. This will release the
horizontal.
tension and cause the clutch lever to contact
the handlebar grip.
EAS20900
BLEEDING THE HYDRAULIC CLUTCH h. Tighten the bleed screw and then release the
SYSTEM clutch lever.
EWA13000 i. Repeat steps (e) to (h) until all of the air bub-
WARNING bles have disappeared from the clutch fluid in
Bleed the hydraulic clutch system whenever: the plastic hose.
• the system was disassembled, j. Tighten the bleed screw to specification.
• a clutch hose was loosened or removed,
Bleed screw (clutch release cylin-
• the clutch fluid level is very low,
der)
T.
• clutch operation is faulty.

R.
6 Nm (0.6 m·kg, 4.3 ft·lb)

TIP
k. Add the recommended clutch fluid to the
• Be careful not to spill any clutch fluid or allow
proper level.
the clutch master cylinder reservoir to over-
Refer to “CHECKING THE CLUTCH FLUID
flow.
• When bleeding the hydraulic clutch system,
make sure there is always enough clutch fluid
before applying the clutch lever. Ignoring this
3-15
ENGINE
EWA13010
air filter element will also affect the throttle
WARNING body synchronization, leading to poor en-
After bleeding the hydraulic clutch system, gine performance and possible overheating.
check the clutch operation.
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ When installing the air filter element into the air
EAS20960
filter case, make sure that the sealing surfaces
REPLACING THE AIR FILTER ELEMENT are aligned to prevent any air leaks.
1. Remove:
• Rider seat 7. Install:
Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank
2. Remove: Refer to “FUEL TANK” on page 6-1.
• Fuel tank • Rider seat
Refer to “FUEL TANK” on page 6-1. Refer to “GENERAL CHASSIS” on page 4-1.
3. Remove: EAS21010
• Air filter case cover “1” CHECKING THE THROTTLE BODY JOINTS
throttle body joints and intake manifolds.
1 1. Remove:
• Rider seat
• Rider seat bracket assembly
• Fuel tank
• Air filter case
4. Remove: 2. Check:
• Air filter element “1” • Throttle body joints “1”
Cracks/damage → Replace.
1
5. Check:
• Air filter element 3. Install:
Damage → Replace. • Air filter case
TIP Refer to “GENERAL CHASSIS” on page 4-1.
The air filter needs more frequent service if you • Fuel tank
are riding in unusually wet or dusty areas. Refer to “FUEL TANK” on page 6-1.
6. Install: • Rider seat
• Air filter case cover Refer to “GENERAL CHASSIS” on page 4-1.
EC1D71002
NOTICE EAS21030
Never operate the engine without the air filter CHECKING THE FUEL LINE
element installed. Unfiltered air will cause The following procedure applies to all of the fuel,
rapid wear of engine parts and may damage air vent and breather hoses.
the engine. Operating the engine without the 1. Remove:
• Rider seat
3-16
ENGINE
• Rider seat bracket assembly 2. Check:

Refer to “GENERAL CHASSIS” on page 4-1. • Cylinder head breather hose “1”
• Fuel tank Cracks/damage → Replace.
Refer to “FUEL TANK” on page 6-1. Loose connection → Connect properly.
2. Check: ECA14920
• Fuel hoses “1” NOTICE

• Air vent hose “2” Make sure the cylinder head breather hose is
• Breather hose “3” routed correctly.
ECA14940
NOTICE
Make sure the fuel tank breather hose is rout-
ed correctly. 1
2
3. Install:
1
• Air filter case
• Fuel tank
• Rider seat
3 Refer to “GENERAL CHASSIS” on page 4-1.
EAS21060
CHECKING THE OIL TANK BREATHER

1 HOSE
1. Remove:
• Right side cover
2. Check:
• Oil tank breather hose “1”
3. Install: Cracks/damage → Replace.
• Fuel tank Loose connection → Connect properly.
ECA14930
NOTICE
• Rider seat Make sure the oil tank breather hose is rout-
Refer to “GENERAL CHASSIS” on page 4-1. ed correctly.
EAS21050
1
CHECKING THE CYLINDER HEAD
BREATHER HOSE
1. Remove:
• Rider seat
• Fuel tank
• Air filter case
3-17
ENGINE
3. Install:
• Right side cover
EAS21080
CHECKING THE EXHAUST SYSTEM (for

XV19S(C)/ XV19CTS(C)) 3 10
The following procedure applies to all of the ex-
haust pipes and gaskets. 4
1. Check:
• Front exhaust pipe “1” LT
LT
• Rear exhaust pipe “2” 11

• Muffler “3” 9 8
• Muffler bracket “4” 5
5 5
• Gaskets “5” 2
Exhaust gas leaks → Replace.
2. Check: 7
5
Tightening torque 6
• Front exhaust pipe nuts “6” 1
• Front exhaust pipe and rear exhaust pipe bolt
“7”
• Rear exhaust pipe nuts “8” EAS1D77002
CHECKING THE EXHAUST SYSTEM (for

• Rear exhaust pipe and muffler bolt “9”
XV19CS(C)/ XV19C(C))
• Muffler and muffler bracket bolts “10”
The following procedure applies to all of the ex-
• Muffler bracket and frame bolts “11”
haust pipes and gaskets.
Front exhaust pipe nut 1. Check:
20 Nm (2.0 m·kg, 14 ft·lb) • Front exhaust pipe “1”
T.
R.
Front exhaust pipe and rear ex- • Rear exhaust pipe “2”
haust pipe bolt • Muffler “3”
20 Nm (2.0 m·kg, 14 ft·lb) • Muffler bracket “4”
Rear exhaust pipe nut Cracks/damage → Replace.
24 Nm (2.4 m·kg, 17 ft·lb) • Gaskets “5”
Rear exhaust pipe and muffler Exhaust gas leaks → Replace.
bolt 2. Check:
20 Nm (2.0 m·kg, 14 ft·lb)
Tightening torque
Muffler and muffler bracket bolt
29 Nm (2.9 m·kg, 21 ft·lb) • Front exhaust pipe nuts “6”
Muffler bracket and frame bolt • Front exhaust pipe and rear exhaust pipe bolt
53 Nm (5.3 m·kg, 38 ft·lb) “7”
LOCTITE® • Rear exhaust pipe nuts “8”
• Rear exhaust pipe and muffler bolt “9”
• Muffler and muffler bracket bolts “10”
• Muffler bracket and frame bolts “11”
• Muffler and frame bolt “12”
3-18
ENGINE
Front exhaust pipe nut

T.
R.
20 Nm (2.0 m·kg, 14 ft·lb)
Front exhaust pipe and rear ex-
haust pipe bolt
20 Nm (2.0 m·kg, 14 ft·lb) 2 4
Rear exhaust pipe nut
24 Nm (2.4 m·kg, 17 ft·lb) 1
Rear exhaust pipe and muffler
bolt
20 Nm (2.0 m·kg, 14 ft·lb) 3
Muffler and muffler bracket bolt 3. Install:
29 Nm (2.9 m·kg, 21 ft·lb) • Horn 1
Muffler bracket and frame bolt Refer to “THROTTLE BODIES” on page 6-6.
53 Nm (5.3 m·kg, 38 ft·lb)
LOCTITE® EAS1D77007
Muffler and frame bolt CHECKING THE CANISTER (for California

20 Nm (2.0 m·kg, 14 ft·lb) only) (for XV19CSC/ XV19CC)
1. Remove:
• Horn 1
Refer to “THROTTLE BODIES” on page 6-6.
2. Check:
12 • Canister “1”
4
• Canister hose “2”
10 • Canister purge hose
3 • Canister breather hose “3”
11 • Fuel tank breather/overflow pipe “4”
LT
5
9 2
8
2
5 5 4
1 2
6
7 1 3
5 6 3. Install:
• Horn 1
EAS21090 Refer to “THROTTLE BODIES” on page 6-6.
CHECKING THE CANISTER (for California
only) (for XV19SC/ XV19CTSC) EAS21100
ADJUSTING THE EXUP CABLES

1. Remove:
1. Remove:
• Horn 1
• EXUP valve pulley cover “1”
2. Check:
• Canister “1”
• Canister purge hose “2”
• Canister breather hose “3”
• Fuel tank breather/overflow hose “4”
3-19
ENGINE
2. Check:
• EXUP system operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the main switch to “ON”.
b. Check that the EXUP valve operates proper-
ly.
TIP
Check that the projection “a” on the EXUP valve 1
pulley contact the stopper “b” (fully-open posi-
tion) and the stopper “c” (fully-closed position).
b. Turn both adjusting bolts “2” in or out until the
specification.
b Turn in “a” →
Free play is increased.
a Turn out “b” →
Free play is decreased.
b 2
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b
3. Check: a
• EXUP cable free play (at the EXUP valve pul-
ley) “a” and “b”
2
EXUP cable free play (at the
EXUP valve pulley)
a: 3 mm (0.12 in) or less c. Tighten both locknuts.
b: 3 mm (0.12 in) or less d. Turn the main switch to “ON” and check that
the projection “c” on the EXUP valve pulley
contacts the stoppers (fully open and fully
closed positions), then stops between the
b lines “d” on the cable holder.
a
c
4. Adjust:
• EXUP cable free play d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• EXUP valve pulley cover
EXUP valve pulley cover bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
3-20
CHASSIS
EAS21140 EWA13070
CHASSIS WARNING
After adjusting the brake pedal position,
EAS21190
ADJUSTING THE REAR DISC BRAKE check that the end of the adjusting bolt “c” is
1. Check: visible through the hole “d”.
• Brake pedal position
(distance “a” from the top of the rider footrest
to the top of the brake pedal)
1
Out of specification → Adjust. a
Brake pedal position

110.0 mm (4.33 in) b
93.0 mm (3.66 in) 2
A
2 1 c
B c. Tighten the locknut.

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

Direction “b” 1. Stand the vehicle on a level surface.
Brake pedal is lowered. TIP
• Make sure the vehicle is upright.
3-21
CHASSIS
2. Remove: ECA13540
• Rider seat NOTICE

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

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

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

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

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

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

a. Fill the brake fluid reservoir to the proper level 6 Nm (0.6 m·kg, 4.3 ft·lb)
with the recommended brake fluid.
b. Install the diaphragm (brake master cylinder k. Fill the brake fluid reservoir to the proper level
reservoir or brake fluid reservoir). with the recommended brake fluid.
c. Connect a clear plastic hose “1” tightly to the Refer to “CHECKING THE BRAKE FLUID
bleed screw “2”. LEVEL” on page 3-21.
3-24
CHASSIS
EWA13110
WARNING Direction “a”

After bleeding the hydraulic brake system, Installed shift rod length increases.
check the brake operation. Direction “b”
Installed shift rod length decreases.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install: TIP
• Rider seat
• Make sure that the exposed thread length “c”
between the locknut and joint on both ends of
EAS21380 the shift rod is 10 mm or less (for XV19S(C)/
ADJUSTING THE SHIFT PEDAL XV19CTS(C)).
TIP • Make sure that the exposed thread length “c”
The shift pedal position is determined by the in- between the locknut and joint on both ends of
stalled shift rod length “a”. the shift rod is 7 mm (for XV19CS(C)/
XV19C(C)).
1. Measure:
• Installed shift rod length “a” A
Incorrect → Adjust. 1
a c
Installed shift rod length
XV19S(C)/ XV19CTS(C): b
312.0–316.0 mm (12.28–12.44 in) 2
XV19CS(C)/ XV19C(C): c
345.0–349.0 mm (13.58–13.74 in)
A
B
1
a c
a
b 2
c
B
B. For XV19CS(C)/ XV19C(C)
a c. Tighten both locknuts.
Locknut (shift rod)

12 Nm (1.2 m·kg, 8.7 ft·lb)
T.
R.
d. Make sure the installed shift rod length is

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

tion.
Rear wheel axle nut

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

STEERING HEAD Steering nut wrench
1. Stand the vehicle on a level surface. 90890-01403
EWA13120 Exhaust flange nut wrench
WARNING YU-A9472
Securely support the vehicle so that there is
no danger of it falling over. Lower ring nut (initial tightening
torque)
T.
TIP
R.
52 Nm (5.2 m·kg, 37 ft·lb)

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

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

R.
18 Nm (1.8 m·kg, 13 ft·lb)

Refer to “FRONT FORK” on page 4-66.
d. Check the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-77.
e. Install the rubber washer “3”.
f. Install the upper ring nut.
g. Finger tighten the upper ring nut “2”, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper EAS21590
ring nut until their slots are aligned. ADJUSTING THE REAR SHOCK ABSORBER
h. Install the lock washer “1”. ASSEMBLY
EWA13120
TIP
WARNING
Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.
Spring preload
ECA13590
NOTICE
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• Spring preload
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Adjust the spring preload with the special
5. Install: wrench “1”.
• Upper bracket ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT FORK” on page 4-66. a. Loosen the locknut “2”.
3-28
CHASSIS
b. Turn the adjusting ring “3” in direction “a” or

“b”. Locknut (rear shock absorber
spring preload adjusting nut)
T.
R.
Direction “a” 30 Nm (3.0 m·kg, 22 ft·lb)
Spring preload is increased (suspen- ECA13600
sion is harder). NOTICE
Direction “b”
Spring preload is decreased (suspen- Always tighten the locknut against the ad-
sion is softer). justing nut and torque it to specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Spring preload adjusting posi- EAS21650
tions CHECKING THE TIRES

Installed spring length The following procedure applies to both of the
Minimum tires.
XV19S(C)/ XV19CTS(C): 1. Check:
162.0 mm (6.38 in) • Tire pressure
XV19CS(C)/ XV19C(C): Out of specification → Regulate.
163.0 mm (6.42 in)
Standard
XV19S(C):
171.0 mm (6.73 in)
XV19CTS(C):
165.0 mm (6.50 in)
172.0 mm (6.77 in)
Maximum
171.0 mm (6.73 in)
EWA13180
172.0 mm (6.77 in) WARNING
• The tire pressure should only be checked
and regulated when the tire temperature
1 equals the ambient air temperature.
• The tire pressure and the suspension must
a
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
b
• Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
c. Installed spring length

c. Tighten the locknut to specification.
3-29
CHASSIS
Tire air pressure (measured on

cold tires)
Loading condition
0–90 kg (0–198 lb)
Front
250 kPa (36 psi) (2.50 kgf/cm²)
Rear
280 kPa (41 psi) (2.80 kgf/cm²)
Loading condition
XV19S(C):
90–210 kg (198–463 lb) 1. Tire tread depth
XV19CTS(C): 2. Side wall
90–181 kg (198–399 lb) 3. Wear indicator
XV19CS(C)/ XV19C(C)
EWA14080
90–204 kg (198–450 lb)
Front WARNING
250 kPa (36 psi) (2.50 kgf/cm²) • Do not use a tubeless tire on a wheel de-
Rear signed only for tube tires to avoid tire fail-
280 kPa (41 psi) (2.80 kgf/cm²) ure and personal injury from sudden
High-speed riding deflation.
Front • When using a tube tire, be sure to install the
250 kPa (36 psi) (2.50 kgf/cm²) correct tube.
Rear • Always replace a new tube tire and a new
280 kPa (41 psi) (2.80 kgf/cm²)
tube as a set.
Maximum load
XV19S(C): • To avoid pinching the tube, make sure the
210 kg (463 lb) wheel rim band and tube are centered in the
XV19CTS(C): wheel groove.
181 kg (399 lb) • Patching a punctured tube is not recom-
XV19C(C)(1US): mended. If it is absolutely necessary to do
195 kg (430 lb) so, use great care and replace the tube as
XV19CS(C)/ XV19C(C)(30B): soon as possible with a good quality re-
204 kg (450 lb) placement.
* Total weight of rider, passenger, cargo
and accessories
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
2. Check:
• Tire surfaces
Damage/wear → Replace the tire.
A. Tire
Wear limit (front) B. Wheel
1.0 mm (0.04 in)
Wear limit (rear) Tube wheel Tube tire only
1.0 mm (0.04 in) Tubeless wheel Tube or tubeless tire
EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
3-30
CHASSIS
should always be by the same manufacturer

and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.
Front tire
Size
130/70R18M/C 63H
XV19CS(C)/ XV19C(C): EAS21670
120/70–21M/C 62H CHECKING THE WHEELS
Manufacturer/model The following procedure applies to both of the
XV19S(C)/ XV19CTS(C): wheels.
DUNLOP/D251F 1. Check:
• Wheel
XV19CS(C)/ XV19C(C): Damage/out-of-round → Replace.
EWA13260
METZELER/880 MARATHON WARNING
Never attempt to make any repairs to the
Rear tire wheel.
Size
XV19S(C)/ XV19CTS(C): TIP
190/60R17M/C 78H After a tire or wheel has been changed or re-
XV19CS(C)/ XV19C(C): placed, always balance the wheel.
210/40R18M/C 73H
Manufacturer/model EAS21690
XV19S(C)/ XV19CTS(C): CHECKING AND LUBRICATING THE

DUNLOP/D251 CABLES
XV19S(C)/ XV19CTS(C): The following procedure applies to all of the in-
BRIDGESTONE/G850 RADIAL G ner and outer cables.
XV19CS(C)/ XV19C(C): EWA13270
METZELER/880 MARATHON WARNING

EWA13210
Damaged outer cable may cause the cable to
WARNING corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
New tires have a relatively low grip on the
as soon as possible.
road surface until they have been slightly
worn. Therefore, approximately 100 km 1. Check:
should be traveled at normal speed before • Outer cable
any high-speed riding is done. Damage → Replace.
2. Check:
TIP • Cable operation
For tires with a direction of rotation mark “1”: Rough movement → Lubricate.
• Install the tire with the mark pointing in the di-
rection of wheel rotation. Recommended lubricant
• Align the mark “2” with the valve installation Engine oil or a suitable cable lu-
point. bricant
TIP
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
3-31
CHASSIS
EAS21700
LUBRICATING THE LEVERS

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

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

moving parts of the sidestand.
EAS21740
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
TIP
Lubricate the pivoting points and contact surfac-
es between the connecting rod and frame and
between the swingarm and frame.
3-32
ELECTRICAL SYSTEM
EAS21750
5. Replace:
ELECTRICAL SYSTEM • Low beam headlight bulb
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EAS21760
CHECKING AND CHARGING THE BATTERY a. Disconnect:

Refer to “ELECTRICAL COMPONENTS” on • Headlight coupler “1”
page 7-69. b. Remove:
• Headlight bulb “2”
EAS21770 EWA13320
CHECKING THE FUSES WARNING

Refer to “ELECTRICAL COMPONENTS” on Since the headlight bulb gets extremely hot,
page 7-69. keep flammable products and your hands
EAS21790
away from the bulb until it has cooled down.
REPLACING THE HEADLIGHT BULBS (for
XV19S(C)/ XV19CTS(C))
1. Remove:
• Windshield (for XV19CTS(C)) 2
2. Remove:
• Headlight cover “1”
1
1
c. Install:
• Headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
ECA13690
NOTICE
Avoid touching the glass part of the head-
3. Disconnect:
light bulb to keep it free from oil, otherwise
• Air temperature sensor coupler “1”
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
1 affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
d. Connect:
• Headlight coupler
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Replace:
• High beam headlight bulb
4. Remove: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Headlight lens unit “1” a. Remove:
• Headlight bulb cover “1”
3-33
ELECTRICAL SYSTEM
b. Disconnect: 10.Install:
• Headlight coupler “1” • Windshield (for XV19CTS(C))
c. Detach: Refer to “GENERAL CHASSIS” on page 4-1.
• Headlight bulb holder “2”
EAS1D77005
REPLACING THE HEADLIGHT BULB (for

1. Remove:
• Headlight lens unit “1”
2
1
d. Remove:
• Headlight bulb
EWA13320
WARNING
Since the headlight bulb gets extremely hot, 2. Disconnect:
keep flammable products and your hands • Headlight coupler “1”
away from the bulb until it has cooled down. 3. Remove:
e. Install: • Headlight bulb cover “2”
light bulb holder.
ECA13690
NOTICE
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened 4. Detach:
with alcohol or lacquer thinner. • Headlight bulb holder “1”
5. Remove:
f. Attach: • Headlight bulb “2”
• Headlight bulb holder EWA13320
g. Connect: WARNING
• Headlight coupler Since the headlight bulb gets extremely hot,
h. Install: keep flammable products and your hands
• Headlight bulb cover away from the bulb until it has cooled down.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• Headlight lens unit
8. Connect:
• Air temperature sensor coupler
9. Install:
• Headlight cover
Headlight cover bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
3-34
ELECTRICAL SYSTEM
6. Install:
A
light bulb holder.
ECA13690
a b
NOTICE
1
affected. If the headlight bulb gets soiled, B
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
7. Attach:
• Headlight bulb holder
8. Install: b a
• Headlight bulb cover
9. Connect: 1
• Headlight coupler
10.Install: A. For XV19S(C)/ XV19CTS(C)
• Headlight lens unit B. For XV19CS(C)/ XV19C(C)
EAS21810
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ADJUSTING THE HEADLIGHT BEAMS
2. Adjust:
1. Adjust:
• Headlight beam (horizontally)
• Headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting bolt “1” in direction “a” or
a. Turn the adjusting bolt “1” in direction “a” or
“b”.
“b”.
Direction “a”
Direction “a” Headlight beam moves to the right.
Headlight beam is raised. Direction “b”
Direction “b” Headlight beam moves to the left.
Headlight beam is lowered.
3-35
ELECTRICAL SYSTEM
b
a 1
b a

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3-36
ELECTRICAL SYSTEM
3-37
CHASSIS
GENERAL CHASSIS.......................................................................................4-1
REMOVING THE WINDSHIELD ............................................................... 4-2
ASSEMBLING THE WINDSHIELD ........................................................... 4-2
INSTALLING THE WINDSHIELD.............................................................. 4-2
REMOVING THE BACKREST ..................................................................4-5
ASSEMBLING THE BACKREST............................................................... 4-5
INSTALLING THE BACKREST .................................................................4-5
CHECKING THE SIDEBAG BRACKET SPRING NUTS........................... 4-8
FRONT WHEEL............................................................................................. 4-19

REMOVING THE FRONT WHEEL.......................................................... 4-23
DISASSEMBLING THE FRONT WHEEL................................................ 4-23
CHECKING THE FRONT WHEEL .......................................................... 4-23
ASSEMBLING THE FRONT WHEEL......................................................4-24
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-24
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-25
REAR WHEEL ...............................................................................................4-27

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

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

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

HANDLING THE REAR SHOCK ABSORBER ........................................ 4-86
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-86
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY AND
SWINGARM ........................................................................................... 4-86
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-87
CHECKING THE CONNECTING ARM AND RELAY ARM.....................4-87
CHECKING THE SWINGARM ................................................................4-87
INSTALLING THE RELAY ARM, REAR SHOCK ABSORBER
ASSEMBLY AND CONNECTING ARMS ............................................... 4-87
INSTALLING THE SWINGARM ..............................................................4-89
BELT DRIVE.................................................................................................. 4-90

REMOVING THE DRIVE BELT AND DRIVE PULLEY ........................... 4-92
CHECKING THE DRIVE BELT ...............................................................4-92
INSTALLING THE DRIVE BELT AND DRIVE PULLEY .......................... 4-92
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the windshield (for XV19CTS(C))
1 5 23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
LT
LT
6
4 23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
LT
LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)

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

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

T.
R.
T.
R.
Order Job/Parts to remove Q’ty Remarks

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

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

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

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

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

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

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

T.
R.
48 Nm (4.8 m • kg, 35 ft • Ib)

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

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

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

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

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

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

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

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

T.
R.
TIP
1 Rider seat 1 rections to clean the leather on the seat.
Polish the dry leather with a soft cloth, and
then treat with Yamaha Mink Oil or another
high-quality leather protectant for increased
water resistance. (XV19C(C) [1US model]
only)
TIP
2 Passenger seat 1 rections to clean the leather on the seat.
Polish the dry leather with a soft cloth, and
then treat with Yamaha Mink Oil or another
high-quality leather protectant for increased
water resistance. (XV19C(C) [1US model]
only)
3 Tool kit 1
4 Tool kit tray 1
5 Rider seat bracket assembly 1
4-9
GENERAL CHASSIS
Removing the seats and side covers
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
2
3
1
T.
R. 7 Nm (0.7 m • kg, 5.1 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LT
6
23 Nm (2.3 m • kg, 17 ft • Ib) 4

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

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

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

T.
R.

6 Right side cover 1
7 Left side cover 1
8 Seat lock cable assembly 1
dure.
4-10
GENERAL CHASSIS
Removing the headlight (for XV19S(C)/ XV19CTS(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)

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

T.
R.

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

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

1 Headlight lens unit 1
2 Headlight coupler 1 Disconnect.
3 Front left turn signal/position light coupler 1 Disconnect.
4 Front right turn signal/position light coupler 1 Disconnect.
5 Main switch coupler 2 Disconnect.
6 Headlight body 1
7 Air temperature sensor coupler 1 Disconnect.
8 Air temperature sensor bracket 1
9 Air temperature sensor 1
10 Headlight bracket 2
11 Spacer 4
dure.
4-12
GENERAL CHASSIS
Removing the battery
4 6 1
5 10
2
7 9
17 16 3
18
15
13 (3)
11
14
19
12 20
19

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

17 Headlight relay 1
18 Turn signal relay 1
19 Plastic locking tie 2
20 Battery box 1
dure.
4-14
GENERAL CHASSIS
Removing the air filter case (for XV19S(C)/ XV19CTS(C))

T.
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
R.
T.
R.
(7) 1
11
6
5
9
12
8 10
13
12
3
7

Rider seat 4-1.
Fuel tank Refer to “FUEL TANK” on page 6-1.
Pressure regulator cover Refer to “THROTTLE BODIES” on page 6-6.
1 Air filter case cover 1
2 Air filter element 1
3 Intake air pressure sensor coupler 1 Disconnect.
4 Intake air pressure sensor hose 1 Disconnect.
5 Intake air pressure sensor 1
6 Intake air pressure sensor bracket 1
7 Cylinder head breather hose 1 Disconnect.
8 Air filter case breather hose 1 1 Disconnect.
10 ISC (idle speed control) unit inlet hose 1 Disconnect.
11 Air filter case bracket 1
12 Air filter case joint clamp screw 2 Loosen.
4-15
GENERAL CHASSIS
Removing the air filter case (for XV19S(C)/ XV19CTS(C))

T.
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
R.
T.
R.
(7) 1
11
6
5
9
12
8 10
13
12
3
7

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

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

15 Fuel tank bracket 2 (front side) 1
16 Air filter case bracket 1
17 Air filter case joint clamp screw 2 Loosen.
18 Air filter case 1
dure.
4-18
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake discs (for XV19S(C)/ XV19CTS(C))
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R
72 Nm (7.2 m kg, 52 ft • Ib)
•
5
T.
R.
6 1
LT
LT
LT
9
2 7
4 1
3 6
8
16 Nm (1.6 m • kg, 11 ft • Ib) (4) LT
5
T.
R.
7
LT
11 12 23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
13
(6)
13
LT
10 11
23 Nm (2.3 m • kg, 17 ft • Ib)

23 Nm (2.3 m • kg, 17 ft • Ib)
T.
LT
R.
(6)
T.
R.
TIP
Place the vehicle on a suitable stand so that
the front wheel is elevated.
1 Front brake hose guide 2

2 Right front brake hose guide bracket 1
3 Left front brake hose guide bracket 1
4 Front fender 1
5 Reflector 2
6 Reflector bracket 2
7 Front brake caliper 2
8 Front wheel axle pinch bolt 1 Loosen.
9 Front wheel axle 1
10 Front wheel 1
11 Collar 2
12 Front brake disc cover 1
4-19
FRONT WHEEL
Removing the front wheel and brake discs (for XV19S(C)/ XV19CTS(C))
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
T.
R.
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R
72 Nm (7.2 m kg, 52 ft • Ib)
•
5
T.
R.
6 1
LT
LT
LT
9
2 7
4 1
3 6
8
16 Nm (1.6 m • kg, 11 ft • Ib) (4) LT
5
T.
R.
7
LT
11 12 23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
13
(6)
13
LT
10 11
23 Nm (2.3 m • kg, 17 ft • Ib)

23 Nm (2.3 m • kg, 17 ft • Ib)
T.
LT
R.
(6)
T.
R.

13 Front brake disc 2
dure.
4-20
FRONT WHEEL
Removing the front wheel and brake discs (for XV19CS(C)/ XV19C(C))
LT
4
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
3 LT 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
6 (4)
T.
R.
2
5 1
9 7 LT
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
72 Nm (7.2 m • kg, 52 ft • lb)

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

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

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

2 Right front brake hose holder bracket 1
3 Left front brake hose holder bracket 1
4 Front fender 1
5 Reflector 2
8 Front wheel axle pinch bolt 1 Loosen.
9 Front wheel axle 1
10 Front wheel 1
11 Collar 2
12 Front brake disc 2
dure.
4-21
FRONT WHEEL
Disassembling the front wheel
New 1
2
LS
3
2
1 New
LS

1 Oil seal 2
2 Wheel bearing 2
3 Spacer 1
For assembly, reverse the disassembly pro-
cedure.
4-22
FRONT WHEEL
EAS21900
c. Remove the wheel bearings “3” with a gener-
REMOVING THE FRONT WHEEL
al bearing puller.
EWA13120
WARNING
2. Loosen:
• Front wheel axle pinch bolt “1”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21920
CHECKING THE FRONT WHEEL

1. Check:
1 • Front wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
3. Remove: EWA13460
• Front brake calipers WARNING

TIP Do not attempt to straighten a bent wheel ax-
Do not apply the brake lever when removing the le.
brake calipers.
4. Elevate:
• Front wheel
TIP
front wheel is elevated.
EAS21910
DISASSEMBLING THE FRONT WHEEL

1. Remove:
• Oil seals 2. Check:
• Wheel bearings • Tire
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Front wheel
a. Clean the outside of the front wheel hub. Damage/wear → Replace.
b. Remove the oil seals “1” with a flathead Refer to “CHECKING THE TIRES” on page
screwdriver. 3-29 and “CHECKING THE WHEELS” on
TIP page 3-31.
3. Measure:
To prevent damaging the wheel, place a rag “2”
• Radial wheel runout “1”
between the screwdriver and the wheel surface.
• Lateral wheel runout “2”
Over the specified limits → Replace.
Radial wheel runout limit

1.0 mm (0.04 in)
Lateral wheel runout limit
0.5 mm (0.02 in)
4-23
FRONT WHEEL
4. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Wheel bearings EAS21970
Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC
place the wheel bearings. BALANCE
• Oil seals TIP
Damage/wear → Replace. • After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
• Adjust the front wheel static balance with the
brake disc installed.
1. Remove:
• Balancing weight(s)
2. Find:
• Front wheel’s heavy spot
TIP
Place the front wheel on a suitable balancing
EAS21960 stand.
ASSEMBLING THE FRONT WHEEL
1. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Spin the front wheel.
• Wheel bearings New b. When the front wheel stops, put an “X1” mark
• Oil seals New at the bottom of the wheel.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seals in
the reverse order of disassembly.
EC1D71011
NOTICE
Do not contact the wheel bearing inner race
“1” or balls “2”. Contact should be made
only with the outer race “3”.
TIP
Use a socket “4” that matches the diameter of
the wheel bearing outer race and oil seal. c. Turn the front wheel 90° so that the “X1” mark
is positioned as shown.
d. Release the front wheel.
e. When the wheel stops, put an “X2” mark at
the bottom of the wheel.
4-24
FRONT WHEEL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure it stays at
each position shown.
f. Repeat steps (d) through (f) several times un-

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

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
LOCTITE®
TIP
Tighten the front brake disc bolts in stages and
in a crisscross pattern.
b. Turn the front wheel 90° so that the heavy

spot is positioned as shown.
2. Check:
• Front brake discs
Refer to “CHECKING THE FRONT BRAKE
c. If the heavy spot does not stay in that posi- DISCS” on page 4-40.
tion, install a heavier weight. 3. Lubricate:
d. Repeat steps (b) and (c) until the front wheel • Oil seal lips
is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Recommended lubricant
4. Check: Lithium-soap-based grease
• Front wheel static balance
4-25
FRONT WHEEL
4. Install:
• Front wheel axle
TIP
Install the tire and wheel with the mark “1” point-
ing in the direction of wheel rotation.
5. Tighten:
• Front wheel axle
• Front wheel axle pinch bolt
Front wheel axle

72 Nm (7.2 m·kg, 52 ft·lb)
T.
R.
Front wheel axle pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb)
EC1D71004
NOTICE
Before tightening the wheel axle, push down
hard on the handlebar several times and
check if the front fork rebounds smoothly.
6. Install:
• Front brake calipers
Front brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)
T.
R.
EWA13500
WARNING
Make sure the brake hose is routed properly.
7. Install:
• Front fender
• Left front brake hose guide bracket
• Right front brake hose guide bracket
TIP
• Temporarily tighten the front fender bolts.
• Apply locking agent (LOCTITE®) to the
threads of the front fender bolts.
8. Tighten:
• Front fender bolts
Front fender bolt

16 Nm (1.6 m·kg, 11 ft·lb)
T.
R.
LOCTITE®
4-26
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear fender
4
1
LT
LT
4 2
LT
LT
4
4
2
3
23 Nm (2.3 m • kg, 17 ft • Ib) 40 Nm (4.0 m • kg, 29 ft • Ib)

T.
T.
R.
R.

T.
T.
R.
R.

Rider seat/Passenger seat/Tool kit tray 4-1.
1 Sub-wire harness 1 coupler 1 Disconnect.
2 Rear fender bracket 2 For XV19S(C)/ XV19CTS(C)
3 Rear fender bracket 2 For XV19CS(C)/ XV19C(C)
4 Dowel pin 4
5 Rear fender assembly 1
dure.
4-27
REAR WHEEL
Removing the rear wheel
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
150 Nm (15.0 m • kg, 110 ft • lb)
T.
R.
6
5 27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
10
8 7
1 S
6
5
11 3
9 2
4
LS
12
4
13
S
14
15
TIP
the rear wheel is elevated.
Muffler Refer to “ENGINE REMOVAL” on page 5-1.

1 Upper drive belt cover 1
2 Rear brake caliper 1
3 Rear brake pad 2
4 Brake pad spring 2
5 Drive belt adjusting locknut 2 Loosen.
6 Drive belt adjusting bolt 2 Loosen.
7 Rear wheel axle nut 1
8 Washer 1
9 Rear wheel axle 1
10 Right drive belt puller 1
11 Left drive belt puller 1
12 Rear brake caliper bracket 1
13 Collar 1 Black
4-28
REAR WHEEL
Removing the rear wheel
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
150 Nm (15.0 m • kg, 110 ft • lb)
T.
R.
6
5 27 Nm (2.7 m • kg, 19 ft • Ib)
T.
R.
10
8 7
1 S
6
5
11 3
9 2
4
LS
12
4
13
S
14
15

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

1 Rear brake disc cover 1
2 Rear brake disc 1
3 Rear wheel pulley 1
4 Oil seal 1
5 Circlip 1
6 Rear wheel drive hub 1
7 Circlip 1
8 Bearing 1
9 Collar 1
10 Bearing 1
11 Rear wheel drive hub damper 6
12 Rear wheel 1
dure.
4-30
REAR WHEEL
Disassembling the rear wheel
New 4 5
6
LS
3
2
1

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

1. Stand the vehicle on a level surface. 1
EWA13120
WARNING
2
TIP
rear wheel is elevated.
EAS22080
2. Remove: DISASSEMBLING THE REAR WHEEL
• Rear brake caliper “1” 1. Remove:
TIP • Oil seals
Do not depress the brake pedal when removing • Wheel bearings
the brake caliper. Refer to “DISASSEMBLING THE FRONT
WHEEL” on page 4-23.
EAS22090
CHECKING THE REAR WHEEL

1. Check:
• Rear wheel axle
• Rear wheel
• Wheel bearings
1 • Oil seals
Refer to “CHECKING THE FRONT WHEEL”
on page 4-23.
3. Loosen: 2. Check:
• Drive belt adjusting locknuts “1” • Tire
• Drive belt adjusting bolts “2” • Rear wheel
Damage/wear → Replace.
Refer to “CHECKING THE TIRES” on page
3-29 and “CHECKING THE WHEELS” on
page 3-31.
3. Measure:
• Radial wheel runout
• Lateral wheel runout
2 1 Refer to “CHECKING THE FRONT WHEEL”
on page 4-23.
Radial wheel runout limit

4. Remove:
1.0 mm (0.04 in)
• Rear wheel axle nut “1” Lateral wheel runout limit
• Rear wheel axle “2” 0.5 mm (0.02 in)
• Rear wheel
TIP ET1D71024
Push the rear wheel forward and remove the CHECKING THE REAR BRAKE CALIPER
drive belt from the rear wheel pulley. BRACKET
1. Check:
• Rear brake caliper bracket
4-32
REAR WHEEL
EAS22110 EAS22150
CHECKING THE REAR WHEEL DRIVE HUB ADJUSTING THE REAR WHEEL STATIC
1. Check: BALANCE
• Rear wheel drive hub TIP
Cracks/damage → Replace. • After replacing the tire, wheel or both, the rear
• Rear wheel drive hub dampers wheel static balance should be adjusted.
Damage/wear → Replace. • Adjust the rear wheel static balance with the
EAS22130 brake disc and rear wheel drive hub installed.
CHECKING AND REPLACING THE REAR
1. Adjust:
WHEEL PULLEY
• Rear wheel static balance
1. Check:
Refer to “ADJUSTING THE FRONT WHEEL
• Rear wheel pulley
STATIC BALANCE” on page 4-24.
Surface plating has come off → Replace the
rear wheel pulley. EAS28770
Bent teeth → Replace the rear wheel pulley. INSTALLING THE REAR WHEEL (DISC)
2. Replace: 1. Lubricate:
• Rear wheel pulley • Rear wheel axle
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Oil seal lips
a. Remove the self-locking nuts and the rear
wheel pulley. Recommended lubricant
b. Clean the rear wheel drive hub with a clean Lithium-soap-based grease
cloth, especially the surfaces that contact the
2. Install:
pulley.
• Rear brake disc
c. Install the new rear wheel pulley.
• Rear brake disc cover
Rear wheel pulley self-locking
nut Rear brake disc bolt
T.
18 Nm (1.8 m·kg, 13 ft·lb)

R.
95 Nm (9.5 m·kg, 68 ft·lb)

T.
R.
LOCTITE®
TIP
TIP
Tighten the self-locking nuts in stages and in a
crisscross pattern.
threads of the brake disc bolts.
• Tighten the brake disc bolts in stages and in a
crisscross pattern.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
LT
EAS22140
ASSEMBLING THE REAR WHEEL

3. Check:
1. Install:
• Rear brake disc
• Wheel bearings New Refer to “CHECKING THE REAR BRAKE
• Oil seals New DISC” on page 4-53.
Refer to “ASSEMBLING THE FRONT 4. Install:
WHEEL” on page 4-24. • Rear wheel axle
• Washer
• Rear wheel axle nut
4-33
REAR WHEEL
TIP
Temporarily tighten the wheel axle nut.
5. Adjust:
• Drive belt slack
Refer to “ADJUSTING THE DRIVE BELT
SLACK” on page 3-25.
6. Tighten:
• Rear wheel axle nut
Rear wheel axle nut

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

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

T.
R.
9 7

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

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

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

1
.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

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

.
R.

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

1 Brake pad clip 2
2 Brake pad pin 1
4 Brake pad 2
5 Brake pad shim 2
6 Brake caliper piston 4
7 Brake caliper piston dust seal 4
8 Brake caliper piston seal 4
9 Bleed screw 1
cedure.
4-39
FRONT BRAKE
EAS22220
e. Measure the deflection 1.5 mm (0.06 in) be-
INTRODUCTION
EWA14100
low the edge of the brake disc.
WARNING
Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-
less absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Never use solvents on internal brake com- 4. Measure:

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

The following procedure applies to both brake
discs.
1. Remove:
• Front wheel 5. Adjust:
Refer to “FRONT WHEEL” on page 4-19. • Brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
2. Check: a. Remove the brake disc.
• Brake disc b. Rotate the brake disc by one bolt hole.
Damage/galling → Replace. c. Install the brake disc.
3. Measure:
• Brake disc deflection Front brake disc bolt
Out of specification → Correct the brake disc 23 Nm (2.3 m·kg, 17ft·lb)
T.
R.
deflection or replace the brake disc. LOCTITE®
Brake disc deflection limit TIP

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

e. If out of specification, repeat the adjustment • Brake pad shims
steps until the brake disc deflection is within (onto the brake pads)
specification. • Brake pads
f. If the brake disc deflection cannot be brought • Brake pad spring
within specification, replace the brake disc. TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Always install new brake pads, brake pad shims,
6. Install: and a brake pad spring as a set.
• Front wheel
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “FRONT WHEEL” on page 4-19. a. Connect a clear plastic hose “1” tightly to the
EAS22270 bleed screw “2”. Put the other end of the hose
REPLACING THE FRONT BRAKE PADS into an open container.
The following procedure applies to both brake b. Loosen the bleed screw and push the brake
calipers. caliper pistons into the brake caliper with your
TIP finger.
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem- 2
ble the brake caliper. 1
1. Measure:
• Brake pad wear limit “a”
Out of specification → Replace the brake
pads as a set.
Brake pad lining thickness (in-

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

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

40 Nm (4.0 m·kg, 29 ft·lb) CALIPERS
T.
R.
The following procedure applies to both of the

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

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

caliper pistons. The following procedure applies to both of the
• Brake caliper cylinders “2” brake calipers.
Scratches/wear → Replace the brake caliper 1. Install:
assembly. • Front brake caliper “1”
• Brake caliper body “3” (temporarily)
Cracks/damage → Replace the brake caliper • Copper washers New
assembly. • Front brake hose “2”
• Brake fluid delivery passages • Front brake hose union bolt “3”
(brake caliper body)
Obstruction → Blow out with compressed air. Front brake hose union bolt
EWA1D77003
32 Nm (3.2 m·kg, 23 ft·lb)
T.
R.
WARNING
EWA1D77008
Whenever a brake caliper is disassembled,
WARNING
replace the piston seals and dust seals.
Proper brake hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE
ROUTING (for XV19S(C)/ XV19CTS(C))” on
page 2-49 and “CABLE ROUTING (for
XV19CS(C)/ XV19C(C))” on page 2-67.
4-43
FRONT BRAKE
ECA14170
NOTICE not enter the brake fluid reservoir. Water
When installing the brake hose onto the will significantly lower the boiling point of
brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.
“a” touches the projection “b” on the brake ECA13540
caliper. NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.
a 5. Bleed:
• Brake system
2 Refer to “BLEEDING THE HYDRAULIC
b BRAKE SYSTEM” on page 3-24.
3 6. Check:
1 • Brake fluid level
2. Remove: recommended brake fluid to the proper level.
• Front brake caliper Refer to “CHECKING THE BRAKE FLUID
3. Install: LEVEL” on page 3-21.
• Brake pads
• Brake pad spring
• Brake pad pin
• Brake pad clips
• Front brake caliper
• Brake hose guide
Brake caliper bolt

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

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

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

CHECKING THE FRONT BRAKE MASTER er bolt
T.
R.
CYLINDER 10 Nm (1.0 m·kg, 7.2 ft·lb)
1. Check:
• Brake master cylinder “1” TIP
Damage/scratches/wear → Replace. • Align the end of the brake master cylinder hold-
• Brake fluid delivery passages er with the punch mark “a” on the handlebar.
(brake master cylinder body) • First, tighten the rear bolt, then the front bolt.
Obstruction → Blow out with compressed air.
a
2
1
2. Check: 2. Install:
• Brake master cylinder kit • Copper washers New
Damage/scratches/wear → Replace. • Front brake hose “1”
3. Check: • Front brake hose union bolt “2”
• Brake master cylinder reservoir
Cracks/damage → Replace. Front brake hose union bolt
• Brake master cylinder reservoir diaphragm 30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
Damage/wear → Replace. EWA1D77008
4. Check: WARNING
• Brake hose Proper brake hose routing is essential to in-
Cracks/damage/wear → Replace. sure safe vehicle operation. Refer to “CABLE
EAS22520 ROUTING (for XV19S(C)/ XV19CTS(C))” on
ASSEMBLING THE FRONT BRAKE MASTER page 2-49 and “CABLE ROUTING (for
CYLINDER XV19CS(C)/ XV19C(C))” on page 2-67.
EWA13520
WARNING TIP
• Before installation, all internal brake com- • Install the brake hose at a right angle to the
ponents should be cleaned and lubricated front brake master cylinder as shown in the il-
with clean or new brake fluid. lustration.
• Never use solvents on internal brake com- • While holding the brake hose, tighten the union
ponents. bolt.
4-45
FRONT BRAKE
• Turn the handlebar to the left and right to make ECA13540
sure the brake hose does not touch other parts NOTICE
(e.g., wire harness, cables, leads). Correct if Brake fluid may damage painted surfaces
necessary. and plastic parts. Therefore, always clean up
A 4. Bleed:
• Brake system
Refer to “BLEEDING THE HYDRAULIC
2 BRAKE SYSTEM” on page 3-24.
1 5. Check:
• Brake fluid level
10–30˚ Below the minimum level mark “a” → Add the
Refer to “CHECKING THE BRAKE FLUID
B LEVEL” on page 3-21.
2
1
15–35˚

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

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

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

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3 1
4 2
16 Nm (1.6 m • kg, 11 ft • Ib)

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

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

T.
R.

Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir hose 1
6 Rear brake master cylinder cover 1
7 Rear brake hose union bolt 1
8 Copper washer 2
9 Rear brake hose 1
10 Rear brake light switch 1
11 Right rider footrest assembly 1 For XV19S(C)/ XV19CTS(C)
12 Right rider footrest assembly 1 For XV19CS(C)/ XV19C(C)
13 Brake rod 1
14 Locknut 1
15 Brake master cylinder bracket 1
4-48
REAR BRAKE
Removing the rear brake master cylinder

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
3 1
4 2
16 Nm (1.6 m • kg, 11 ft • Ib)

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

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

T.
R.

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

1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Circlip 1
5 Brake hose joint 1
6 O-ring 1
7 Brake master cylinder body 1
cedure.
4-50
REAR BRAKE
Removing the rear brake caliper
4 3
4 2 New
30 Nm (3.0 m • kg, 22 ft • Ib)
T.
1
R.
27 Nm (2.7 m • kg, 19 ft • Ib)

T.
R.

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

1 Brake caliper piston 1
2 Brake caliper piston dust seal 1
3 Brake caliper piston seal 1
4 Bleed screw 1
cedure.
4-52
REAR BRAKE
EAS22560
INTRODUCTION
EWA14100
DISCS” on page 4-40.
WARNING
Brake disc thickness limit
Disc brake components rarely require disas- 5.5 mm (0.22 in)
sembly. Therefore, always follow these pre-
ventive measures: 5. Adjust:
• Never disassemble brake components un- • Brake disc deflection
less absolutely necessary. Refer to “CHECKING THE FRONT BRAKE
• If any connection on the hydraulic brake DISCS” on page 4-40.
system is disconnected, the entire brake
system must be disassembled, drained, Brake disc bolt
cleaned, properly filled, and bled after reas- 18 Nm (1.8 m·kg, 13 ft·lb)
T.
R.
sembly. LOCTITE®
• Never use solvents on internal brake com-
ponents. 6. Install:
• Use only clean or new brake fluid for clean- • Rear wheel
ing brake components. Refer to “REAR WHEEL” on page 4-27.
• Brake fluid may damage painted surfaces EAS22580
and plastic parts. Therefore, always clean REPLACING THE REAR BRAKE PADS
up any spilt brake fluid immediately. TIP
• Avoid brake fluid coming into contact with When replacing the brake pads, it is not neces-
the eyes as it can cause serious injury. sary to disconnect the brake hose or disassem-
• FIRST AID FOR BRAKE FLUID ENTERING ble the brake caliper.
THE EYES:
• Flush with water for 15 minutes and get im- 1. Measure:
mediate medical attention. • Brake pad wear limit “a”
Out of specification → Replace the brake
EAS22570 pads as a set.
CHECKING THE REAR BRAKE DISC
1. Remove: Brake pad lining thickness (in-
• Rear wheel ner)
5.8 mm (0.23 in)
Refer to “REAR WHEEL” on page 4-27.
Limit
2. Check: 0.8 mm (0.03 in)
• Brake disc Brake pad lining thickness (out-
Damage/galling → Replace. er)
3. Measure: 5.8 mm (0.23 in)
• Brake disc deflection Limit
Out of specification → Correct the brake disc 0.8 mm (0.03 in)
deflection or replace the brake disc.
DISCS” on page 4-40.
Brake disc deflection limit

XV19S(C)/ XV19CTS(C)/ a
0.15 mm (0.0059 in)
XV19C(C)(1US):
0.10 mm (0.0039 in)
4. Measure:
• Brake disc thickness 2. Install:
Measure the brake disc thickness at a few dif- • Brake pads
ferent locations. • Brake pad springs
Out of specification → Replace.
4-53
REAR BRAKE
TIP Refer to “BLEEDING THE HYDRAULIC

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

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

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

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

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

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

EWA1D77008
EWA1D77005
WARNING
WARNING Proper brake hose routing is essential to in-
Whenever a brake caliper is disassembled, sure safe vehicle operation. Refer to “CABLE
replace the brake caliper piston seal and ROUTING (for XV19S(C)/ XV19CTS(C))” on
dust seal. page 2-49 and “CABLE ROUTING (for
ECA14170
NOTICE
When installing the brake hose onto the
brake caliper “1”, make sure the brake pipe
“a” touches the projection “b” on the brake
caliper.
4-55
REAR BRAKE
5. Bleed:
• Brake system
b
6. Check:
• Brake fluid level
1
3 a 2 LEVEL” on page 3-21.
2. Remove:
• Rear brake caliper
3. Install:
• Brake pads
• Brake pad springs
• Rear brake caliper bolts
• Rear brake caliper a
Refer to “REPLACING THE REAR BRAKE
PADS” on page 4-53.
Rear brake caliper bolt 7. Check:

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

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

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

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

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

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

• Rear brake hose union bolt “3” Brake fluid may damage painted surfaces
Rear brake hose union bolt
30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
3. Bleed:
EWA1D77008
• Brake system
WARNING
Proper brake hose routing is essential to in- BRAKE SYSTEM” on page 3-24.
sure safe vehicle operation. Refer to “CABLE 4. Check:
ROUTING (for XV19S(C)/ XV19CTS(C))” on • Brake fluid level
page 2-49 and “CABLE ROUTING (for Below the minimum level mark “a” → Add the
XV19CS(C)/ XV19C(C))” on page 2-67. recommended brake fluid to the proper level.
4-57
REAR BRAKE
5. Check:
• Brake pedal operation
tem.
6. Adjust:
Refer to “ADJUSTING THE REAR DISC
BRAKE” on page 3-21.
7. Adjust:
• Rear brake light operation timing
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-23.
4-58
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar (for XV19S(C)/ XV19CTS(C))
28 Nm (2.8 m • kg, 20 ft • Ib) 1

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

T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

T.
R.

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

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

T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

T.
R.

15 Handlebar grip 1
16 Upper handlebar holder 1
17 Handlebar 1
18 Hose guide 1
19 Lower handlebar holder 1
dure.
4-60
HANDLEBAR
Removing the handlebar (for XV19CS(C)/ XV19C(C))

B 3 Nm (0.3 m • kg, 2.2 ft • Ib)
28 Nm (2.8 m • kg, 20 ft • Ib) 3
T.R
.
T.
R.
6 LS
A
3
19 7
14 11 10
8 9
20
5 4 LS
13 8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
21
T.
R.
15 LT 21
10 16 23 Nm (2.3 m • kg, 17 ft • Ib)
12
T.
R.
15
17 18
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

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

T.
R.

Headlight bracket 4-1.
3 Rearview mirror 2
4 Front brake light switch connector 2 Disconnect.
6 Front brake master cylinder assembly 1
7 Throttle cable holder 1
8 Right handlebar switch 1
9 Throttle cable 2
10 Grip end 2
11 Throttle grip 1
14 Clutch master cylinder assembly 1
15 Left handlebar switch 1
4-61
HANDLEBAR
Removing the handlebar (for XV19CS(C)/ XV19C(C))

B 3 Nm (0.3 m • kg, 2.2 ft • Ib)
28 Nm (2.8 m • kg, 20 ft • Ib) 3
T.R
.
T.
R.
6 LS
A
3
19 7
14 11 10
8 9
20
5 4 LS
13 8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
21
T.
R.
15 LT 21
10 16 23 Nm (2.3 m • kg, 17 ft • Ib)
12
T.
R.
15
17 18
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

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

T.
R.

16 Handlebar grip 1
17 Main switch cover 1
18 Lead holder 2
19 Upper handlebar holder 1
20 Handlebar 1
21 Lower handlebar holder 2
dure.
A: Except for XV19C(C) (1US model)

B: For XV19C(C) (1US model)
4-62
HANDLEBAR
EAS22860
REMOVING THE HANDLEBAR

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

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

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

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

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

T.
R.
19 Nm (1.9 m • kg, 13 ft • Ib)

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

T.
R.

the front fork legs.
Windshield bracket (left and right) For XV19CTS(C)
Lower handlebar holder Refer to “HANDLEBAR” on page 4-59.
Front wheel Refer to “FRONT WHEEL” on page 4-19.
1 Upper bracket cover 1
2 Upper bracket pinch bolt 4 Loosen.
3 Cap bolt 1 Loosen.
4 Steering stem nut 1
5 Upper bracket 1
6 Upper front fork cover 1
7 Upper front fork cover spacer 1
8 Upper front fork cover washer 1
9 Lower front fork cover nut 2
10 Lower bracket pinch bolt 2 Loosen.
11 Lower front fork cover 1
4-66
FRONT FORK
Removing the front fork legs (for XV19S(C)/ XV19CTS(C))

6
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
T.
115 Nm (11.5 m • kg, 85 ft • lb)
R.
19 Nm (1.9 m • kg, 13 ft • Ib)

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

T.
R.

12 Front fork leg 1
dure.
4-67
FRONT FORK
Removing the front fork legs (for XV19CS(C)/ XV19C(C))

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
19 Nm (1.9 m • kg, 13 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib) 1
T.
R.
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
1
2 3
2 3 1
1
3
4 3
4
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
19 Nm (1.9 m • kg, 13 ft • Ib)
T.
R.

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

1 Protector 1 For XV19CS(C)/ XV19C(C)
2 Cap bolt 1
3 O-ring 1
4 Spacer 1
5 Spring seat 1
6 Fork spring 1
7 Dust seal 1
8 Oil seal clip 1
9 Damper rod bolt 1
10 Copper washer 1
11 Damper rod 1
12 Rebound spring 1
13 Inner tube 1
14 Oil seal 1
15 Washer 1
16 Outer tube bushing 1
4-69
FRONT FORK
Disassembling the front fork legs
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
2
New 3
4
7 New
13
8 New
5
14 New
6 15
16 New
17 New
11 20
18
19
12
10 New
9
LT
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.

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

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

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

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

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

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

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

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

• Upper bracket pinch bolts
3 Upper bracket pinch bolt

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

R.
LOCTITE®
23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
• Upper bracket cover bolts

3. Remove:
• Upper bracket Upper bracket cover bolt
4. Tighten: 16 Nm (1.6 m·kg, 11 ft·lb)
T.
R.
• Lower front fork cover nuts LOCTITE®
Lower front fork cover nut EWA13680
7 Nm (0.7 m·kg, 5.1 ft·lb) WARNING

T.
R.
Make sure the brake hoses are routed prop-

5. Install: erly.
• Upper front fork cover “1”
• Upper bracket
4-75
FRONT FORK
EAS1D77008
INSTALLING THE FRONT FORK LEGS (for

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

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

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

T.
R.

Lower handlebar holder Refer to “HANDLEBAR” on page 4-59.
Upper bracket/Front fork legs Refer to “FRONT FORK” on page 4-66.
1 Headlight bracket and throttle cable guide 1
3 Front brake hose joint 1
4 Lock washer 1
5 Upper ring nut 1
6 Rubber washer 1
7 Lower ring nut 1
8 Lower bracket 1
9 Upper bearing cover 1
10 Upper bearing 1
11 Lower bearing 1
12 Dust seal 1
4-77
STEERING HEAD
Removing the lower bracket (for XV19S(C)/ XV19CTS(C)

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

T.
R.

13 Bearing outer race 2
dure.
4-78
STEERING HEAD
Removing the lower bracket (for XV19CS(C)/ XV19C(C))

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
165 Nm (16.5 m • kg, 120 ft • lb) 11
T.
R.
LS
8
13
10 Nm (1.0 m • kg, 7.2 ft • Ib) 12
T.
R.
10
T.
1st 52 Nm (5.2 m • kg, 37 ft • lb)
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)
R.
9
LS
16 Nm (1.6 m • kg, 11 ft • Ib) 14
LS
T.
15
R.
7 16
17
19
20
10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 23
T.R
.
5 18
LT
4
23
2 LT 21
3
LS
1 7 22
LT 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
R.
R.

Lower handlebar holders Refer to “HANDLEBAR” on page 4-59.
Front fork legs Refer to “FRONT FORK” on page 4-66.
1 Plate 1
3 Front brake hose joint 1
4 Front brake hose joint holder 1
5 Lower bracket cover 1
6 Lead guide 1
7 Front turn signal/position light 2
8 Main switch cover bracket 1
9 Cable guide 1
10 Main switch 1
11 Steering stem bolt 1
12 Washer 1
13 Upper bracket 1
14 Lock washer 1
15 Upper ring nut 1
4-79
STEERING HEAD
Removing the lower bracket (for XV19CS(C)/ XV19C(C))

7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
165 Nm (16.5 m • kg, 120 ft • lb) 11
T.
R.
LS
8
13
10 Nm (1.0 m • kg, 7.2 ft • Ib) 12
T.
R.
10
T.
1st 52 Nm (5.2 m • kg, 37 ft • lb)
2nd 18 Nm (1.8 m • kg, 13 ft • Ib)
R.
9
LS
16 Nm (1.6 m • kg, 11 ft • Ib) 14
LS
T.
15
R.
7 16
17
19
20
10 Nm (1.0 m • kg, 7.2 ft • Ib) 6 23
T.R
.
5 18
LT
4
23
2 LT 21
3
LS
1 7 22
LT 7 Nm (0.7 m • kg, 5.1 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
R.
R.

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

90890-01403
Exhaust flange nut wrench
YU-A9472
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23120 4. Check:
CHECKING THE STEERING HEAD • Upper bracket
1. Wash: • Lower bracket
• Bearings (along with the steering stem)
• Bearing races Bends/cracks/damage → Replace.
Recommended cleaning solvent EAS23140
Kerosene INSTALLING THE STEERING HEAD (for

2. Check: 1. Lubricate:
• Bearings • Upper bearing
• Bearing races • Lower bearing
Damage/pitting → Replace. • Bearing races
3. Replace:
• Bearings Recommended lubricant
• Bearing races Lithium-soap-based grease
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering 2. Install:
head pipe with a long rod “1” and hammer. • Lower ring nut “1”
4-81
STEERING HEAD
• Rubber washer “2” • Upper ring nut “3”

• Upper ring nut “3” • Lock washer “4”
• Lock washer “4” Refer to “CHECKING AND ADJUSTING
Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-27.
THE STEERING HEAD” on page 3-27.
3. Install:
3. Install: • Upper bracket
• Front brake hose joint “1” • Steering stem bolt
• Front brake hose guide “2” TIP
TIP Temporarily tighten the steering stem bolt.
• Make sure that the projection “a” on the lower
4. Install:
bracket contacts the side “b” of the front brake
• Front fork legs
hose joint “1”.
• Align the projection “c” on the front brake hose
guide with the hole “d” in the lower bracket. TIP
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem bolt
1
Steering stem bolt
165 Nm (16.5 m·kg, 120 ft·lb)
T.
R.
d c 2 6. Install:
b a • Front brake hose guide “1”
TIP
4. Install:
• Front fork legs Align the projection “a” on the front brake hose
• Upper bracket guide with the hole “b” in the lower bracket.
EAS1D77009 b
INSTALLING THE STEERING HEAD (for
1. Lubricate:
a
• Upper bearing
• Lower bearing
• Bearing races
Recommended lubricant 1
2. Install:
• Lower ring nut “1”
• Rubber washer “2”
4-82
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
ET1D71001

Removing the rear shock absorber assembly and swingarm
48 Nm (4.8 m • kg, 35 ft • Ib)

A 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6
T.R
T.
B 10 Nm (1.0 m • kg, 7.2 ft • Ib)

R.
.
7
5 LT
LT
10
LS 7 Nm (0.7 m • kg, 5.1 ft • Ib)

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

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

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

Rear wheel Refer to “REAR WHEEL” on page 4-27.
Exhaust pipes Refer to “ENGINE REMOVAL” on page 5-1.
Brake master cylinder bracket Refer to “REAR BRAKE” on page 4-47.
Loosen.
Engine mounting nut (rear lower side) Refer to “ENGINE REMOVAL” on page 5-1.
1 Horn 1 coupler 1 Disconnect.
2 Horn 1 1
3 Passenger footrest (left and right) 2 For XV19S(C) only
TIP
4 O2 sensor lead guide 1 Pass the O2 sensor lead through the guide.
For XV19S(C)/ XV19CTS(C)
5 Rear brake hose guide 1 For XV19S(C)/ XV19CTS(C)
6 Rear brake hose holder 1 For XV19CS(C)/ XV19C(C)
7 Rear brake hose guide 1 For XV19CS(C)/ XV19C(C)
8 Self-locking nut/Bolt/Spacer/Washer 1/1/1/1
9 Pivot shaft nut/Washer 1/1
4-83
Removing the rear shock absorber assembly and swingarm
48 Nm (4.8 m • kg, 35 ft • Ib)

A 7 Nm (0.7 m • kg, 5.1 ft • Ib) 6
T.R
T.
B 10 Nm (1.0 m • kg, 7.2 ft • Ib)

R.
.
7
5 LT
LT
10
LS 7 Nm (0.7 m • kg, 5.1 ft • Ib)

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

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

10 Pivot shaft 1
11 Rear shock absorber and swingarm assembly 1
12 Lower drive belt cover 1
dure.
A: For XV19S(C)/ XV19CTS(C)

B: For XV19CS(C)/ XV19C(C)
4-84
Removing the rear shock absorber and swingarm
LS
3
New
2
LS
1
40 Nm (4.0 m • kg, 29 ft • Ib) 2
T.
R.
LS
13
9 12 1
4
LS
12
LS
6 14 13
5 11
8 New
14 14 LS
6 9
LS
7 10 14
6
LS
8 59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
6 5 4
59 Nm (5.9 m • kg, 43 ft • Ib)
T.
R.
LS

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

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

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

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

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

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

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

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

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

Recommended lubricant side)
Lithium-soap-based grease 98 Nm (9.8 m·kg, 71 ft·lb)
Connecting arm nut (front side)
2. Install: 59 Nm (5.9 m·kg, 43 ft·lb)
• Bearings “1”
6. Adjust:
(to swingarm)
Installed depth “a” Refer to “ADJUSTING THE DRIVE BELT
1.0 mm (0.04 in) SLACK” on page 3-25.
4-89
BELT DRIVE
EAS23510
BELT DRIVE
Removing the drive belt and drive pulley
T.
R.
T.
R.
63 Nm (6.3 m • kg, 45 ft • Ib)
T.
R.
9
10
13 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(3) 6
7
8
LT
LT
LT 5
7
8 12 (3)
New 11 3
E 4 1
140 Nm (14.0 m • kg, 100 ft • lb)
T.
R.
(4)
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
(6)

Rear wheel Refer to “REAR WHEEL” on page 4-27.
Refer to “REAR SHOCK ABSORBER AS-
Rear shock absorber assembly and swingarm SEMBLY AND SWINGARM” on page 4-83.
1 Rectifier/regulator cover 1
2 Lead cover 1
3 Stator coil coupler 1 Disconnect.
4 Rectifier/regulator coupler 1 Disconnect.
5 Rectifier/regulator 1
6 Drive pulley cover 1
7 Slider 2
8 Dowel pin 2
9 Transfer gear case bracket 1
10 Drive belt 1
11 Drive pulley nut 1
12 Conical spring washer 1
4-90
BELT DRIVE
Removing the drive belt and drive pulley

T.
R.
T.
R.
63 Nm (6.3 m • kg, 45 ft • Ib)
T.
R.
9
10
13 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(3) 6
7
8
LT
LT
LT 5
7
8 12 (3)
New 11 3
E 4 1
140 Nm (14.0 m • kg, 100 ft • lb)
T.
R.
(4)
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
(6)

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

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

140 Nm (14.0 m·kg, 100 ft·lb)
T.
R.
TIP
• When tightening the drive pulley nut, press
down on the brake pedal so the drive pulley
does not move.
• Stake the drive pulley nut “1” at a cutout “a” in
the middle driven shaft.
5. Adjust:
Refer to “ADJUSTING THE DRIVE BELT
SLACK” on page 3-25.
4-93
ENGINE
ENGINE REMOVAL ........................................................................................5-1

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

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

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

REMOVING THE PISTON ...................................................................... 5-49
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-49
CHECKING THE PISTON RINGS........................................................... 5-50
CHECKING THE PISTON PINS..............................................................5-51
INSTALLING THE PISTONS AND CYLINDERS .................................... 5-51
CLUTCH ........................................................................................................5-53
REMOVING THE CLUTCH ..................................................................... 5-64
REMOVING THE PRIMARY DRIVE GEAR ............................................5-64
REMOVING THE LEFT BALANCER DRIVE GEAR ...............................5-64
CHECKING THE FRICTION PLATES.....................................................5-65
CHECKING THE CLUTCH PLATES .......................................................5-65
CHECKING THE CLUTCH SPRINGS.....................................................5-66
CHECKING THE CLUTCH HOUSING ....................................................5-67
CHECKING THE CLUTCH BOSS........................................................... 5-67
CHECKING THE PRESSURE PLATE ....................................................5-67
CHECKING THE CLUTCH PUSH RODS ............................................... 5-67
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-67
CHECKING THE PRIMARY DRIVEN GEAR ..........................................5-67
CHECKING THE LEFT BALANCER GEARS..........................................5-68
INSTALLING THE LEFT BALANCER DRIVE GEAR ..............................5-68
INSTALLING THE PRIMARY DRIVE GEAR...........................................5-69
INSTALLING THE CLUTCH.................................................................... 5-70
DISASSEMBLING THE CLUTCH MASTER CYLINDER ........................ 5-71
CHECKING THE CLUTCH MASTER CYLINDER................................... 5-71
ASSEMBLING THE CLUTCH MASTER CYLINDER ..............................5-72
INSTALLING THE CLUTCH MASTER CYLINDER.................................5-72
REMOVING THE CLUTCH RELEASE CYLINDER ................................5-73
CHECKING THE CLUTCH RELEASE CYLINDER .................................5-73
ASSEMBLING THE CLUTCH RELEASE CYLINDER............................. 5-74
INSTALLING THE CLUTCH RELEASE CYLINDER ...............................5-74
SHIFT SHAFT................................................................................................5-76
CHECKING THE SHIFT SHAFT ............................................................. 5-77
CHECKING THE STOPPER LEVER ......................................................5-77
INSTALLING THE SHIFT SHAFT ........................................................... 5-77
GENERATOR AND STARTER CLUTCH......................................................5-78

REMOVING THE GENERATOR ............................................................. 5-80
REMOVING THE STARTER CLUTCH ...................................................5-80
CHECKING THE STARTER CLUTCH ....................................................5-80
CHECKING THE TORQUE LIMITER......................................................5-81
INSTALLING THE STARTER CLUTCH .................................................. 5-81
INSTALLING THE GENERATOR............................................................ 5-81
ELECTRIC STARTER ...................................................................................5-83

CHECKING THE STARTER MOTOR .....................................................5-85
ASSEMBLING THE STARTER MOTOR................................................. 5-86
TRANSFER GEAR CASE ............................................................................. 5-87

REMOVING THE MIDDLE DRIVEN SHAFT...........................................5-92
CHECKING THE MIDDLE DRIVE........................................................... 5-92
CHECKING THE OIL STRAINER ........................................................... 5-92
CHECKING THE TRANSFER GEAR OIL PUMP.................................... 5-92
CHECKING THE OIL PIPES ................................................................... 5-93
ASSEMBLING THE TRANSFER GEAR OIL PUMP ...............................5-93
INSTALLING THE TRANSFER GEAR CASE .........................................5-93
CRANKCASE ................................................................................................5-95
DISASSEMBLING THE CRANKCASE....................................................5-98
CHECKING THE CRANKCASE ..............................................................5-98
CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-98
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE .......................... 5-98
CHECKING THE OIL STRAINERS ......................................................... 5-98
CHECKING THE ENGINE OIL PUMP DRIVEN GEAR........................... 5-98
INSTALLING THE BEARING RETAINERS............................................. 5-99
ASSEMBLING THE CRANKCASE.......................................................... 5-99
OIL PUMP....................................................................................................5-101
CHECKING THE OIL PUMP .................................................................5-104
CHECKING THE RELIEF VALVE .........................................................5-104
CHECKING THE BALL SPRING AND RELIEF VALVE SPRING .........5-104
CHECKING THE OIL STRAINER .........................................................5-105
ASSEMBLING THE OIL PUMP.............................................................5-105
INSTALLING THE OIL PUMP ...............................................................5-106
CRANKSHAFT ............................................................................................5-107
REMOVING THE CONNECTING RODS ..............................................5-108
CHECKING THE CRANKSHAFT AND CONNECTING RODS.............5-108
INSTALLING THE CONNECTING RODS.............................................5-111
INSTALLING THE CRANKSHAFT ASSEMBLY....................................5-112
TRANSMISSION..........................................................................................5-113
CHECKING THE SHIFT FORKS...........................................................5-117
CHECKING THE SHIFT DRUM ASSEMBLY........................................5-117
CHECKING THE TRANSMISSION .......................................................5-117
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ............................5-118
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ....5-118
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the muffler and exhaust pipes (for XV19S(C)/ XV19CTS(C))
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
29 Nm (2.9 m • kg, 21 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

T.
R.
5
7 LT
6
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
44 Nm (4.4 m • kg, 32 ft • Ib)
T.
R.
8 12 New S
LT
LT 1
10
9 New 2 New
4
New 15
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib) 11 LT

LT
14
T.R
.

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

T.
R.

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

T.
R.
29 Nm (2.9 m • kg, 21 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

T.
R.
5
7 LT
6
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
44 Nm (4.4 m • kg, 32 ft • Ib)
T.
R.
8 12 New S
LT
LT 1
10
9 New 2 New
4
New 15
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib) 11 LT

LT
14
T.R
.

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

T.
R.

15 Gasket 1
dure.
5-2
ENGINE REMOVAL
Removing the muffler and exhaust pipes (for XV19CS(C)/ XV19C(C))
T.
T.
R.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
6
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.R
.
LT
LT
5
10
New 9
8
2 4 7 LS
New
24 Nm (2.4 m • kg, 17 ft • Ib) 13
T.
R.
11 New
New LS
1 12
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
15 Nm (1.5 m • kg, 11 ft • Ib)

T.R
.

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

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

T.
T.
R.
R.

Rider seat/Left side cover/Battery box/Air filter Refer to “GENERAL CHASSIS” on page
case 4-1.
Fuel tank/Sub-fuel tank Refer to “FUEL TANK” on page 6-1.
Throttle body/Intake manifold/Pressure regula- Refer to “THROTTLE BODIES” on page 6-6.
tor bracket/Rollover valve/Canister
Rear brake master cylinder bracket Refer to “REAR BRAKE” on page 4-47.
Drive pulley Refer to “BELT DRIVE” on page 4-90.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Drain.
Transfer gear oil Refer to “CHANGING THE TRANSFER
GEAR OIL” on page 3-14.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-83.
1 Cylinder-#1 ignition coil cover 1
2 Spark plug cap 2
3 Ignition coil connector 4 Disconnect.
4 Cylinder-#1 left ignition coil 1
5 Cylinder-#1 right ignition coil 1
5-4
ENGINE REMOVAL
Removing the cylinder-#1 ignition coils and sidestand (for XV19S(C)/ XV19CTS(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
LT LT
LT
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
1
5 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4 2 9
3 10
3
LT
6
11
16 Nm (1.6 m • kg, 11 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
16
17
18 New
14 12
19
LT
LT
LT 15
LT
LT 8
63 Nm (6.3 m • kg, 45 ft • Ib) 48 Nm (4.8 m • kg, 35 ft • Ib) 13
T.
T.
R.
R.

T.
T.
R.
R.

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

T.
R.

Rider seat/Left side cover/Battery box/Air filter Refer to “GENERAL CHASSIS” on page
case 4-1.
Throttle body/Intake manifold/Pressure regula- Refer to “THROTTLE BODIES” on page 6-6.
tor bracket/Rollover valve/Canister
Rear brake master cylinder bracket Refer to “REAR BRAKE” on page 4-47.
Drain.
page 3-11.
Drain.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-83.
1 Right ignition coil cover 1
2 Spark plug cap 2
5-6
ENGINE REMOVAL
Removing the right ignition coils and sidestand (for XV19CS(C)/ XV19C(C))
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
LT
T.
R.
5 2
LT
1 2
4 3
3
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
LT
6
11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
9
10
12
14
13
7
LT
LT
LT
15
LT
LT 8
T.
R.
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

6 Right ignition coil bracket 1
Except for California
8 Horn 1 1 Except for California
9 Horn 2 coupler 1
10 Horn 2 1
11 Shift rod 1
12 Rear brake light switch coupler 1
13 Shift pedal assembly 1
14 Sidestand switch 1
15 Sidestand 1
dure.
5-7
ENGINE REMOVAL
ET1D71029
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
INSTALLING THE SHIFT PEDAL ASSEMBLY a. Fit EXUP cable 1 into the EXUP cable brack-
1. Assemble: (for XV19S(C)/ XV19CTS(C)) et slot indicated by the “1” casting mark and
• Shift pedal (heel side) “1” fit EXUP cable 2 into the slot indicated by the
• Shift pedal (toe side) “2” “2” casting mark.
Shift pedal (heel side) bolt TIP
13 Nm (1.3 m·kg, 9.4 ft·lb) EXUP cable 2 is identified by the cutouts “a” in
T.
R.
its adjusting bolt.

TIP
Align the mark “a” on the pin on the toe side with 1
the mark “b” on the heel side.
2
1 b a
2
a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

Shift pedal bolt

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

• Shift rod length
Refer to “ADJUSTING THE SHIFT PEDAL”
on page 3-25.
EAS1D71001
INSTALLING THE EXUP CABLES

1. Install:
• EXUP cable 1 “1”
• EXUP cable 2 “2”
5-8
ENGINE REMOVAL
Removing the oil cooler and oil filter bracket

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

T.
T.
R.
R.

1 Oil filter cartridge 1
2 Oil cooler outlet hose 1 For XV19S(C)/ XV19CTS(C)
3 Oil cooler inlet hose 1 For XV19S(C)/ XV19CTS(C)
4 Oil cooler 1 For XV19S(C)/ XV19CTS(C)
5 Oil cooler bracket 1 For XV19S(C)/ XV19CTS(C)
6 Oil filter bolt 1
7 Oil filter bracket 1
dure.
5-9
ENGINE REMOVAL
ET1D71028
CHECKING THE OIL COOLER (for XV19S(C)/

XV19CTS(C))
1. Check:
• Oil cooler fins
Obstruction → Clean.
Apply compressed air to the rear of the oil
cooler.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flathead
screwdriver.
2. Check:
• Oil cooler inlet hose
• Oil cooler outlet hose
5-10
ENGINE REMOVAL
Disconnecting the leads

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

T.
T.
R.
R.

Refer to “TRANSFER GEAR CASE” on
Drive pulley case page 5-87.
1 Spark plug cap 2
2 Stator coil lead 1
3 Neutral switch coupler 1 Disconnect.
4 Neutral switch lead 1
5 Lead holder bracket 1
6 Wire harness guide 1
7 Throttle cable guide 1
8 Starter motor lead 1
9 Horn 1 lead 1
10 Rear brake light switch lead 1
11 Sidestand switch lead 1
12 Crankshaft position sensor coupler 1 Disconnect.
13 Crankshaft position sensor lead 1
14 Rectifier/regulator lead 1
5-11
ENGINE REMOVAL
Disconnecting the leads

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

T.
T.
R.
R.

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

A 59 Nm (5.9 m • kg, 43 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
90 Nm (9.0 m • kg, 65 ft • Ib)
T.
B 66 Nm (6.6 m • kg, 48 ft • lb)
R.
T.R
.
66 Nm (6.6 m • kg, 48 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) 98 Nm (9.8 m • kg, 71 ft • lb)
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
R.
LT 2
19 6
8 22 2
12 E 17
1 3 5
13 20 15 18
24
23 4
E
11 21 16
25
10
18
LT
14
9
LT
7
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

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

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

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

Transfer gear case page 5-87.
1 Engine mounting bolt (right upper side) 2
2 Engine mounting bolt (left upper side) 2
3 Engine bracket bolt (right upper side) 2
4 Engine bracket (right upper side) 1
5 Engine bracket bolt (left upper side) 2
6 Engine bracket (left upper side) 1
7 Engine mounting nut (front upper side) 1
8 Engine mounting bolt (front upper side) 1
9 Engine cross-member bracket bolt 2
10 Engine cross-member bracket 1
11 Engine bracket nut (front upper side) 4
12 Engine bracket bolt (front upper side) 4
13 Engine bracket (front upper side) 2
5-13
ENGINE REMOVAL
Removing the engine

A 59 Nm (5.9 m • kg, 43 ft • lb) 53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
90 Nm (9.0 m • kg, 65 ft • Ib)
T.
B 66 Nm (6.6 m • kg, 48 ft • lb)
R.
T.R
.
66 Nm (6.6 m • kg, 48 ft • Ib)
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) 98 Nm (9.8 m • kg, 71 ft • lb)
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
T.
R.
LT 2
19 6
8 22 2
12 E 17
1 3 5
13 20 15 18
24
23 4
E
11 21 16
25
10
18
LT
14
9
LT
7
30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

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

T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)

T.
R.

14 Engine mounting nut (rear upper side) 1
15 Engine mounting bolt (rear upper side) 1
16 Engine bracket nut (rear upper side) 2
17 Engine bracket bolt (rear upper side) 2
18 Engine bracket (rear upper side) 2
19 Engine mounting nut (front lower side) 1
20 Spacer bolt 1 Loosen.
21 Engine mounting bolt (front lower side) 1
22 Engine mounting nut (rear lower side) 1
23 Engine mounting bolt (rear lower side) 1
24 Washer 1
25 Engine 1
dure.

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

Engine mounting nut (rear lower Refer to “TRANSFER GEAR CASE” on page
T.
R.
side) 5-87.
Engine mounting nut (front lower
• Drive pulley
side)
90 Nm (9.0 m·kg, 65 ft·lb) • Transfer gear case bracket
Engine bracket nut (rear upper Refer to “BELT DRIVE” on page 4-90.
side) 9. Tighten:
53 Nm (5.3 m·kg, 38 ft·lb) • Engine bracket nuts (front upper side) “3”
Engine mounting nut (rear upper • Engine cross-member bracket bolts “5”
side) • Engine mounting nut (front upper side) “7”
98 Nm (9.8 m·kg, 71 ft·lb)
Engine mounting bolt (left upper Engine bracket nut (front upper
side) side)
T.
R.
66 Nm (6.6 m·kg, 48 ft·lb) 53 Nm (5.3 m·kg, 38 ft·lb)
LOCTITE® Engine cross-member bracket
Engine mounting bolt (right up- bolt
per side) 30 Nm (3.0 m·kg, 22 ft·lb)
XV19S(C)/ XV19CTS(C): LOCTITE®
59 Nm (5.9 m·kg, 43 ft·lb) Engine mounting nut (front upper
XV19CS(C)/ XV19C(C): side)
66 Nm (6.6 m·kg, 48 ft·lb) 98 Nm (9.8 m·kg, 71 ft·lb)
side)
53 Nm (5.3 m·kg, 38 ft·lb) 3
Engine bracket bolt (right upper 7
side)
2 6
53 Nm (5.3 m·kg, 38 ft·lb)
1
5. Install: 2
5
• Engine brackets (front upper side) “1” 4
• Engine bracket bolts (front upper side) “2” 5
• Engine bracket nuts (front upper side) “3” 1
• Engine cross-member bracket “4”
• Engine cross-member bracket bolts “5”
• Engine mounting bolt (front upper side) “6”
• Engine mounting nut (front upper side) “7”
TIP
Do not fully tighten the bolts and nuts.
6. Install:
• Lead holder bracket
• Lead
(removed during engine removal)
TIP
To install and route the leads, refer to “CABLE
page 2-49 and “CABLE ROUTING (for
7. Install:
• Transfer gear case
5-16
CAMSHAFTS
EAS23750
CAMSHAFTS
Removing the camshaft sprocket cover
1 1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
1
2
1
(5)
2
2
(3)
9
8
New 10
5 (3)
New
7 4
LS
6
T.
R.
T.
R.
3 18 Nm (1.8 m • kg, 13 ft • Ib)

T.
R.

Air filter case 4-1.
Muffler/Exhaust pipes Refer to “ENGINE REMOVAL” on page 5-1.
1 Spark plug cap 4 Disconnect.
2 Spark plug 4
3 Shift pedal assembly 1 For XV19S(C)/ XV19CTS(C)
4 Damper cover 1
5 Damper 1
6 Timing mark accessing screw 1
7 Crankshaft end screw 1
8 Camshaft sprocket cover 1
9 Dowel pin 2
10 Camshaft sprocket cover gasket 1
dure.
5-17
CAMSHAFTS
Removing the cylinder head covers

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

T.
R.

1 Cylinder head breather hose 1
2 Oil tank breather hose 1 Disconnect.
3 Wire harness guide 1
4 Fuel tank damper 1
5 Fuel outlet hose 1 Disconnect.
6 Cylinder head cover bolt 8 l = 40 mm (1.57 in)
7 Cylinder head cover bolt 20 l = 60 mm (2.36 in)
8 Rear cylinder head cover 1
9 Front cylinder head cover 1
10 Cylinder head cover gasket 2
11 Dowel pin 4
dure.
5-18
CAMSHAFTS
Removing the push rods and rocker arms

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

1 Rear rocker arm base assembly 1
2 Front rocker arm base assembly 1
3 Rocker arm base gasket 2
4 Dowel pin 4
5 Pull rod 1 3 l = 286.5 mm (11.280 in) pink painting
6 Pull rod 2 1 l = 288.5 mm (11.358 in) sky blue painting
7 Rocker arm shaft 4
8 Rocker arm 1 2
9 Rocker arm 2 2
10 Locknut 4
11 Adjusting screw 4
12 Rear rocker arm base 1
13 Front rocker arm base 1
dure.
5-19
CAMSHAFTS
Removing the valve lifters

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

Refer to “CYLINDERS AND PISTONS” on
Front cylinder page 5-48.
1 Push rod cover 2
2 O-ring 2
3 O-ring 2
4 Seal 2
5 Rear valve lifter case 1
6 Front valve lifter case 1
7 Valve lifter 4
dure.
5-20
CAMSHAFTS
Removing the camshafts and right balancer
18
20
40 Nm (4.0 m • kg, 29 ft • Ib)
T.
R.
19 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
17 New New LS
16 New
15
M
21
7
6
5
18 4 8
9
2
E New 3 E
11
14
(7) 1
13 E
12
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

T.
T.
R.
R.

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

T.
T.
R.
R.

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

1 Circlip 2
2 Washer 2
3 Decompression cam spring 2
4 Decompression cam 2
5 Decompression pin 2
6 Front cylinder camshaft 1
7 Rear cylinder camshaft 1
cedure.
5-23
CAMSHAFTS
ET1D71030
REMOVING THE CYLINDER HEAD COVERS

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

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

1. Loosen:
• Camshaft driven gear bolt “1”
TIP
c. Check the camshaft drive gear mark “c” posi- • Place a folded copper washer “2” between the
tion and camshaft driven gear mark “d” posi- teeth of the camshaft drive gear and camshaft
tion as shown. driven gear in order to lock them.
If the marks are not aligned, turn the crank- • Do not damage the teeth of the camshaft drive
shaft counterclockwise 360 degrees and re- and camshaft driven gears.
check step (b).
5-24
CAMSHAFTS
TIP
1 • Place a folded copper washer “3” between the
teeth of the right balancer drive gear and right
balancer driven gear in order to lock them.
• Place a folded copper washer “4” between the
2 balancer driven gear in order to lock them.
• Do not damage the teeth of the right balancer
drive and right balancer driven gears.
2. Remove:
• Camshaft driven gear
• Straight key
TIP
Cover the crankcase hole with a clean rag to 3
prevent the straight key from falling into the
crankcase. 1
3. Loosen:
• Front cylinder camshaft gear bolt “1”
TIP
teeth of the front cylinder camshaft gear and
rear cylinder camshaft gear in order to lock
them.
• Do not damage the teeth of the front cylinder
camshaft and rear cylinder camshaft gears. 2 4
2 1
6. Remove:
• Right balancer driven gear
• Camshaft drive gear
• Right balancer drive gear
• Straight keys
TIP
Cover the crankcase hole with a clean rag to
4. Remove: prevent the straight keys from falling into the
• Rear cylinder camshaft gear crankcase.
• Front cylinder camshaft gear 7. Remove:
• Straight key • Oil delivery pipe 1 “1”
TIP • Camshaft cover “2”
Cover the crankcase hole with a clean rag to TIP
prevent the straight key from falling into the Loosen each bolt 1/4 of a turn at a time, in stag-
crankcase. es and in a crisscross pattern. After all of the
5. Loosen: bolts are fully loosened, remove them.
• Camshaft drive gear bolt “1”
• Right balancer driven gear bolt “2”
5-25
CAMSHAFTS
EAS23860 3. Measure:
CHECKING THE CAMSHAFTS • Camshaft journal diameter (crankcase side)
1. Check: “a”
• Cam Out of specification → Replace the camshaft.
Blue discoloration/pitting/scratches → Re-
place the camshaft. Camshaft journal diameter
2. Measure: (crankcase side)
• Cam dimensions A “a” and B “b” 24.957–24.980 mm (0.9826–
Out of specification → Replace the camshaft. 0.9835 in)
Camshaft lobe dimensions

Intake A a
42.532–42.632 mm (1.6745–
1.6784 in)
Limit a
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 4. Measure:
42.530–42.630 mm (1.6744– • Camshaft journal diameter (camshaft cover
1.6783 in) side) “a”
Limit Out of specification → Replace the camshaft.
42.430 mm (1.6705 in)
Exhaust B Camshaft journal diameter (cam-
35.950–36.050 mm (1.4154– shaft cover side)
1.4193 in) 27.957–27.980 mm (1.1007–
Limit 1.1016 in)
35.850 mm (1.4114 in)
5. Measure:
• Crankcase hole inside diameter “a”
Out of specification → Replace the crank-
case.
5-26
CAMSHAFTS
TIP
Crankcase hole inside diameter
25.000–25.021 mm (0.9843– Calculate the clearance by subtracting the cam-
0.9851 in) shaft journal diameter (camshaft cover side)
from the camshaft cover hole inside diameter.
Camshaft to camshaft cover

clearance
0.020–0.064 mm (0.0008–0.0025
in)
a a
9. Check:
• Camshaft drive gears
• Camshaft driven gears
• Front cylinder camshaft gears
6. Measure: • Rear cylinder camshaft gears
• Camshaft cover hole inside diameter “a” Chips/pitting/roughness/wear → Replace the
Out of specification → Replace the camshaft defective part(s).
cover. EAS23890
CHECKING THE ROCKER ARMS AND

Camshaft cover hole inside diam- ROCKER ARM SHAFTS
eter The following procedure applies to all of the
28.000–28.021 mm (1.1024– rocker arms and rocker arm shafts.
1.1032 in) 1. Check:
• Rocker arm
a a Damage/wear → Replace.
2. Check:
• Rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrication
system.
3. Measure:
• Rocker arm inside diameter “a”
7. Calculate: Rocker arm inside diameter
• Camshaft-to-crankcase clearance 18.000–18.018 mm (0.7087–
Out of specification → Replace the defective 0.7094 in)
part(s).
TIP
Calculate the clearance by subtracting the cam-
shaft journal diameter (crankcase side) from the
crankcase hole inside diameter.
Camshaft to crankcase clearance

0.020–0.064 mm (0.0008–0.0025
in)
8. Calculate:
• Camshaft to camshaft cover clearance 4. Measure:
Out of specification → Replace the defective • Rocker arm shaft outside diameter “a”
part(s). Out of specification → Replace.
5-27
CAMSHAFTS
Rocker arm shaft outside diame-

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

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

1. Check:
• Rocker arm base
3. Measure:
EAS23910 • Valve lifter outside diameter “a”
CHECKING THE PUSH RODS Out of specification → Replace.
1. Check:
• Push rod Valve lifter outside diameter (in-
• Push rod end take)
Bends/damage → Replace. 22.962–22.974 mm (0.9040–
2. Measure: 0.9045 in)
• Push rod runout Valve lifter outside diameter (ex-
Out of specification → Replace. haust)
22.962–22.974 mm (0.9040–
Valve push rod runout 0.9045 in)
0.3 mm (0.012 in)
5-28
CAMSHAFTS
• O-ring
Damage/wear → Replace the seal and O-
ring as a set.
EAS23980
CHECKING THE DECOMPRESSION SYSTEM

1. Check:
• Decompression system
TIP
• Check that the decompression pin “1” projects
4. Measure: from the camshaft.
• Valve lifter case inside diameter “a” • Check that the decompression cam “2” and de-
Out of specification → Replace. compression pin “1” moves smoothly.
Valve lifter hole inside diameter 1

(intake)
23.000–23.021 mm (0.9055–
0.9063 in)
Valve lifter hole inside diameter
(exhaust)
2
23.000–23.021 mm (0.9055–
0.9063 in)
a 2. Check:
• Decompression cam
• Decompression pin
ET1D71031
CHECKING THE DECOMPRESSION CAM

SPRING
The following procedure applies to all of the de-
compression cam springs.
5. Calculate: 1. Measure:
• Valve lifter-to-valve lifter case clearance • Decompression cam spring free length “a”
TIP Out of specification → Replace the decom-
Calculate the clearance by subtracting the valve pression cam spring.
lifter outside diameter from the valve lifter case
inside diameter. Decompression cam spring
Free length
Above 0.072 mm (0.0028 in) → Replace the 20.0 mm (0.79 in)
defective part(s). Limit
19.0 mm (0.75 in)
Valve-lifter-to-valve-lifter-hole
clearance
0.026–0.059 mm (0.0010–0.0023
in)
EAS23930
CHECKING THE PUSH ROD COVER

1. Check:
• Push rod cover
Cranks/damage → Replace.
• Seal
5-29
CAMSHAFTS
2. Measure:
2
• Compressed decompression cam spring
force “a”
Out of specification → Replace the decom-
pression cam spring. 1
Decompression cam spring
Installed compression spring
force
0.1335–0.1631 N (0.0300–0.0367
lb) (0.0136–0.0166 kgf)
Installed length 3. Install:
8.0 mm (0.31 in) • Straight keys
• Right balancer drive gear “1”
• Right balancer driven gear “2”
• Camshaft driven gear
TIP
• Cover the crankcase hole with a clean rag to
prevent the straight keys from falling into the
crankcase.
• Align the punch mark “a” on the right balancer
drive gear “1” with the punch mark “b” on the
right balancer driven gear “2”.
b. Installed length
EAS23990
CHECKING THE OIL DELIVERY PIPE

1. Check: b a
• Oil delivery pipe 1 2
Damage → Replace.
Obstruction → Wash and blow out with com- 1
pressed air.
• O-rings
Damage/wear → Replace. 4. Tighten:
EAS24030 • Camshaft drive gear bolt “1”
INSTALLING THE CAMSHAFTS • Right balancer driven gear bolt “2”
1. Install:
• Camshafts Camshaft drive gear bolt
60 Nm (6.0 m·kg, 43 ft·lb)
T.
TIP
R.
Right balancer driven gear bolt

Lubricate molybdenum disulfide oil onto the 40 Nm (4.0 m·kg, 29 ft·lb)
camshaft journals and lobes.
2. Install: TIP
• Camshaft cover 1 “1” • Lubricate the camshaft drive gear bolt and right
• Oil delivery pipe 1 “2” balancer driven gear bolt threads with engine
TIP oil.
Tighten the camshaft cover bolts in stages and • Place a folded copper washer “3” between the
in a crisscross pattern. teeth of the right balancer drive gear and right
5-30
CAMSHAFTS
• Do not damage the teeth of the right balancer

drive and right balancer driven gears.
• After tightening the camshaft driven gear bolt, 3
4
remove the copper washer to clean the teeth of 5
the right balancer drive gear and right balancer 6 New
driven gear.
6. Tighten:
• Front cylinder camshaft gear bolt “1”
1
Front cylinder camshaft gear bolt
40 Nm (4.0 m·kg, 29 ft·lb)
3
T.
R.
TIP
teeth of the front cylinder camshaft gear and
rear cylinder camshaft gear in order to lock
them.
• Do not damage the teeth of the front cylinder
4
camshaft and rear cylinder camshaft gears.
2 • After tightening the front cylinder camshaft
gear bolt, remove the copper washer to clean
the teeth of the front cylinder camshaft and rear
cylinder camshaft gears.
5. Install:
• Rear cylinder camshaft gear “1”
• Front cylinder camshaft gear “2” 1
• Washer “3”
• Conical spring washer “4”
• Washer “5”
2
• Circlip “6” New
TIP
• Align the projection “a” on the washer “3” with
the punch mark “b” on the front cylinder cam-
shaft gear. 7. Install:
• Install the conical spring washer “4” as shown • Straight key
in the illustration. • Camshaft driven gear “1”
• Lubricate the front cylinder camshaft gear bolt TIP
threads with engine oil. • Cover the crankcase hole with a clean rag to
prevent the straight key from falling into the
2 1 crankcase.
b • Align the punch mark “a” on the camshaft driv-
en gear “1” with the punch mark “b” on the
camshaft drive gear “2”.
• Insert a cross-headed screwdriver into one of
the holes in the outer camshaft driven gear and
rotate the gear until the teeth of both driven
a
3 gears are aligned. The teeth of both camshaft
driven gears must be aligned for installation.
5-31
CAMSHAFTS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Fill a container with kerosene and place the
1 valve lifter into the container as shown.
Pump the plunger side of the valve lifter with
a press a number of times to let in kerosene.
ECA14630
b NOTICE
2 • Do not pump the valve lifter excessively.
• Kerosene is highly flammable.
1. Kerosene
8. Tighten: 2. Valve lifter
• Camshaft driven gear bolt “1” b. Install the valve lifter into the engine.
ECA14650
Camshaft driven gear bolt NOTICE

60 Nm (6.0 m·kg, 43 ft·lb)
T.
Be sure to install the valve lifter in its appro-

R.
priate position.
TIP
• Place a folded copper washer “2” between the c. Start the engine and warm it up.
teeth of the camshaft drive gear and camshaft d. Stop the engine.
driven gear in order to lock them. e. Remove the camshaft sprocket cover.
• Do not damage the teeth of the camshaft drive f. Rotate the camshaft until the punch mark “1”
and camshaft driven gears. on the camshaft driven gear aligns with the
• After tightening the camshaft driven gear bolt, punch mark on the camshaft drive gear as
remove the copper washer to clean the teeth of shown. This is the condition in which piston
the camshaft drive and camshaft driven gears. #1 is at top dead center (TDC).
TIP
The crankshaft can be rotated smoothly when
1 the spark plugs are removed.
EWA12880
WARNING
2 Be careful since the engine is hot.
g. With piston #1 at TDC, count the indicated
number of gear teeth and place marks “2”
through “5” on the camshaft driven gear as
shown. When these marks align between the
EAS24050 centers of the camshaft drive and driven
BLEEDING A VALVE LIFTER gears, the corresponding valve lifter is at its
A valve lifter must be bled in the following cases. highest point.
• When installing a new valve lifter
• When the valve lifter leaks oil
1. Bleed:
• Valve lifter
5-32
CAMSHAFTS
10
11
1918 17 16 15
9
12
8
7
19 14
13
6
18 13
5
14
17 12
4
4
15
11
3
16
16
2
15 10
1
2 1 1
14 9
1918 1
13 8
12 3 7
1 19
11
4 3
5 6
17 8
10 5
2 1 2
5
9 4
16
8
6
3
15
7
7 2
14
8
1
13
6 5
12
1
9
10
11
4 3 2
1. Piston #1 TDC punch mark 1. Piston #1 TDC punch mark

2. Cylinder #2 intake valve at its highest point 2. Cylinder #2 intake valve at its highest point
3. Cylinder #1 exhaust valve at its highest point
i. Leave the camshaft drive and driven gears
4. Cylinder #1 intake valve at its highest point
aligned for five minutes to allow the valve lift-
5. Cylinder #2 exhaust valve at its highest point
er to bleed.
h. Rotate the crankshaft until the mark (on the j. If necessary, repeat steps (h) and (i) to bleed
camshaft driven gear) for the valve lifter to be other valve lifters.
bled aligns with the camshaft drive gear as ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
shown. EAS24060
Example: INSTALLING THE VALVE LIFTERS

For bleeding the cylinder #2 intake valve lift- 1. Install:
er, align mark “2” as shown. • Front valve lifter case
• Rear valve lifter case
• Valve lifters
Valve lifter case bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
LOCTITE®
TIP
• Install the valve lifter in the correct place.
• After installing the valve lifters, fill the tops of
them with engine oil.
5-33
CAMSHAFTS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Put the rocker arm base on the cylinder head.
b. Install the push rods.
TIP
• Be sure to correctly install the push rods be-
tween the rocker arms and valve lifters as
shown. The illustration is viewed from the right
side of the vehicle.
E
• The lengths of push rod 1 and push rod 2 are
different. Therefore, be sure to install them in
2. Install: the proper position.
• Push rod covers “1” • Lubricate the push rod end balls with engine
TIP oil.
Install the push rod covers so that their paint
marks “a” are facing towards the cylinder heads.
a a
1
1
EAS24070
INSTALLING THE ROCKER ARMS AND

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

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

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

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

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

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

Bolts “5”: l = 60 mm (2.36 in)
5
4
5 2
5
5
5 1
4
5
3 5
3
5-35
CYLINDER HEADS
EAS24110
CYLINDER HEADS
Removing the cylinder heads
T.
R.
T.
R.
1
2
LT
LT
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) (3)
T.
R.
11
60 Nm (6.0 m • kg, 43 ft • Ib)
T.
R.
12
New 7
13 New
5 New
New 9
10
3 New 4
A 59Nm (5.9 m • kg, 43 ft • lb)
New 5
T.
B 66Nm (6.6 m • kg, 48 ft • lb)

R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
6 New
8 17 Nm (1.7 m • kg, 12 ft • Ib)
T.R
.
New 9
10 21 Nm (2.1 m • kg, 15 ft • Ib)
T.
R.

Cylinder-#1 ignition coil bracket Refer to “ENGINE REMOVAL” on page 5-1.
Throttle bodies/Intake manifolds Refer to “THROTTLE BODIES” on page 6-6.
Cylinder head covers/Rocker arms Refer to “CAMSHAFTS” on page 5-17.
1 Engine bracket (right upper side) 1
2 Engine bracket (left upper side) 1
3 Engine temperature sensor 1
4 Oil pipe 1 1
5 Copper washer 4
6 Copper washer 2
7 Rear cylinder head 1
8 Front cylinder head 1
9 Cylinder head gasket 2
10 Dowel pin 4
11 Rear exhaust pipe joint cover 1
12 Rear exhaust pipe joint 1
5-36
CYLINDER HEADS
Removing the cylinder heads

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

R.
20 Nm (2.0 m • kg, 14 ft • Ib)

T.
R.
6 New
8 17 Nm (1.7 m • kg, 12 ft • Ib)
T.R
.
New 9
10 21 Nm (2.1 m • kg, 15 ft • Ib)
T.
R.

13 Rear exhaust pipe gasket 1
dure.

5-37
CYLINDER HEADS
EAS24140
REMOVING THE CYLINDER HEADS

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

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

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

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

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

17 Nm (1.7 m·kg, 12 ft·lb)
T.
R.
2. Install:
• Cylinder heads • Oil pipe union bolts (M10)
• Washers
• Cylinder head nuts Oil pipe union bolt (M10)
21 Nm (2.1 m·kg, 15 ft·lb)
T.
TIP
R.
Lubricate the cylinder head nuts and washers TIP

with engine oil.
Tighten the three union bolts evenly, and then
3. Tighten: torque them to specification.
• Cylinder head nuts
5. Install:
Cylinder head nut • Engine bracket (right upper side)
60 Nm (6.0 m·kg, 43 ft·lb) • Engine bracket bolts (right upper side)
T.
R.
• Engine mounting bolts (right upper side)

TIP • Engine bracket (left upper side)
Tighten the cylinder head nuts in the proper • Engine bracket bolts (left upper side)
tightening sequence as shown and torque them • Engine mounting bolts (left upper side)
in two stages. TIP
A threads of the engine mounting bolts (left up-
per side).
• Do not fully tighten the bolts.
3 2
6. Tighten:
• Engine mounting bolts (right upper side)
• Engine mounting bolts (left upper side)
1 4
• Engine bracket bolts (right upper side)
• Engine bracket bolts (left upper side)
5-39
CYLINDER HEADS
Engine mounting bolt (right up-

T.
R.
per side)
59 Nm (5.9 m·kg, 43 ft·lb)
66 Nm (6.6 m·kg, 48 ft·lb)
Engine mounting bolt (left upper
side)
66 Nm (6.6 m·kg, 48 ft·lb)
LOCTITE®
Engine bracket bolt (right upper
side)
53 Nm (5.3 m·kg, 38 ft·lb)
side)
53 Nm (5.3 m·kg, 38 ft·lb)
5-40
VALVES AND VALVE SPRINGS
EAS24270

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

The following procedure applies to both cyl-
inders.
Cylinder heads Refer to “CYLINDER HEADS” on page 5-36.
1 Valve cotter 8
2 Upper spring seat 4
3 Valve spring 4
4 Intake valve 2
5 Exhaust valve 2
6 Valve stem seal 4
7 Lower spring seat 4
8 Valve guide 4
dure.
5-41
EAS24280
3. Remove:
REMOVING THE VALVES
• Upper spring seat “1”
• Valve spring “2”
valves and related components.
• Valve “3”
TIP • Valve stem seal “4”
Before removing the internal parts of the cylinder • Lower spring seat “5”
head (e.g., valves, valve springs, valve seats), TIP
make sure the valves properly seal.
Identify the position of each part very carefully so
1. Check: that it can be reinstalled in its original place.
• Valve sealing
Leakage at the valve seat → Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”
on page 5-44.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent “a” into the intake and
exhaust ports.
b. Check that the valves properly seal.
TIP
There should be no leakage at the valve seat “1”.
EAS24290
CHECKING THE VALVES AND VALVE

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECA13810
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crank-
case.
• For reference during installation, put an identi- EAS24410
fication mark on each piston crown. CHECKING THE CYLINDERS AND PISTONS
• Before removing the piston pin, deburr the pis- The following procedure applies to all of the cyl-
ton pin clip’s groove and the piston’s pin bore inders and pistons.
area. If both areas are deburred and the piston 1. Check:
pin is still difficult to remove, remove it with the • Piston wall
piston pin puller set “4”. • Cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
Piston pin puller set rings as a set.
90890-01304 2. Measure:
Piston pin puller
• Piston-to-cylinder clearance
YU-01304
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
3 bore gauge.
TIP
1 Measure cylinder bore “C” by taking side-to-side
2 and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Bore
100.000–100.010 mm (3.9370–
3.9374 in)
Taper limit
0.050 mm (0.0020 in)
Out of round limit
0.050 mm (0.0020 in)
“C” = maximum of D1–D6

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

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

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

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

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

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

Drain.
page 3-11.
Left side cover 4-1.
Horn 1/Canister For California only
Left rider footrest assembly/Shift rod/Sidestand Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “GENERATOR AND STARTER
Generator cover CLUTCH” on page 5-78.
Drive pulley case page 5-87.
1 Crankshaft position sensor coupler 1 Disconnect.
2 Shift arm 1
3 Protector 1 For XV19CS(C)/ XV19C(C)
4 Fuel tank breather/overflow pipe bracket 1 For XV19CS(C)/ XV19C(C)
For USA only
5 Fuel tank breather/overflow pipe holder bracket 1 For XV19CS(C)/ XV19C(C)
5-53
CLUTCH
Removing the clutch cover
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.
2
8
3
8
(5)
New 7 5 4
6
10 Nm (1.0 m • kg, 7.2 ft • Ib) (11) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
R.
R.

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

1 Oil seal 1
2 Bearing 1
3 Crankshaft position sensor lead holder 3
4 Crankshaft position sensor 1
dure.
5-55
CLUTCH
Removing the clutch
LS
29
28 27 26
25
New
20
24 E
E
21 19 105 Nm (10.5 m • kg, 75 ft • lb)
22 18
T.
R.
23 17
24
16 15
33 10 14 New
New
34
11
32
31 30
8 13
10 8 5 12
4
E 9
8 2 E
7
5
6 New
85 Nm (8.5 m • kg, 61 ft • Ib)
LS
T.
R.
3 2
E E 1
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.

1 Clutch spring retainer 1
2 Clutch spring 3
3 Pressure plate 1
4 Short clutch push rod 1
5 Friction plate 1 2 Inside diameter: 135 mm (5.31 in)
6 Clutch plate 1 1
7 Clutch plate 2 1
9 Clutch plate 3 1
10 Clutch plate 4 7
11 Clutch boss nut 1
13 Washer 1
14 Wire circlip 1
16 Clutch damper spring 1
17 Clutch damper spring seat 1
5-56
CLUTCH
Removing the clutch
LS
29
28 27 26
25
New
20
24 E
E
21 19 105 Nm (10.5 m • kg, 75 ft • lb)
22 18
T.
R.
23 17
24
16 15
33 10 14 New
New
34
11
32
31 30
8 13
10 8 5 12
4
E 9
8 2 E
7
5
6 New
85 Nm (8.5 m • kg, 61 ft • Ib)
LS
T.
R.
3 2
E E 1
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.

18 Clutch boss 1
19 Thrust washer 1 1
20 Clutch housing 1
21 Circlip 1
22 Washer 1
23 Oil pump drive gear 1
24 Dowel pin 2
25 Bearing 1
26 Collar 1
27 Thrust washer 2 1
28 Ball 1
29 Long push rod 1
30 Spacer 1
31 Crankshaft position sensor rotor 1
32 Primary drive gear 1
33 Straight key 1
5-57
CLUTCH
Removing the clutch
LS
29
28 27 26
25
New
20
24 E
E
21 19 105 Nm (10.5 m • kg, 75 ft • lb)
22 18
T.
R.
23 17
24
16 15
33 10 14 New
New
34
11
32
31 30
8 13
10 8 5 12
4
E 9
8 2 E
7
5
6 New
85 Nm (8.5 m • kg, 61 ft • Ib)
LS
T.
R.
3 2
E E 1
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.R
.

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

1 Left balancer idle gear shaft holder 1
2 Dowel pin 2
3 O-ring 2
4 Left balancer idle gear 1
5 Left balancer idle gear shaft 1
6 Left balancer drive gear 1
7 Straight key 1
8 Left balancer driven gear 1
9 Left balancer weight 1 1
10 Left balancer weight 2 1
11 Left balancer driven gear housing 1
12 Gasket 1
dure.
5-59
CLUTCH
Removing the clutch master cylinder
4 1
30 Nm (3.0 m • kg, 22 ft • Ib)

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

T.
R.

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

1 Clutch master cylinder push rod 1
2 Dust boot 1
3 Circlip 1
4 Washer 1
5 Clutch master cylinder kit 1
6 Clutch master cylinder body 1
cedure.
5-61
CLUTCH
Removing the clutch release cylinder
19 Nm (1.9 m • kg, 13 ft • Ib)
T.
R.
A 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.R
B 10 Nm (1.0 m • kg, 7.2 ft • Ib)
.
New 3
1
2
6
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
5
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Drain.
Clutch fluid Refer to “BLEEDING THE HYDRAULIC
1 Clutch pipe union bolt cap 1
2 Clutch pipe union bolt 1
3 Copper washer 2
4 Clutch pipe 1
5 Clutch release cylinder 1
6 Dowel pin 2
dure.

5-62
CLUTCH
Disassembling the clutch release cylinder
6 Nm (0.6 m • kg, 4.3 ft • Ib)
T.
R.
BF
6
New 4
2
S
1

1 Boots 1
2 Clutch release cylinder piston 1
3 Clutch release cylinder spring 1
4 Clutch release cylinder piston seal 1
5 Bleed screw 1
6 Clutch release cylinder body 1
cedure.
5-63
CLUTCH
EAS25080
REMOVING THE CLUTCH TIP

1. Loosen: While holding the generator rotor “2” with the
• Clutch boss nut “1” sheave holder “3”, loosen the primary drive gear
TIP
bolt.
While holding the clutch boss “2” with the univer-
sal clutch holder “3”, loosen the clutch boss nut. Sheave holder
90890-01701
Primary clutch holder
Universal clutch holder YS-01880-A
90890-04086
YM-91042
3 2
1
1
2. Remove:
• Clutch boss nut “1”
• Washer “3”
• Wire circlip “4”
• Clutch plate 4 “5”
3
• Friction plate 3 “6”
2
• Clutch damper spring “7”
• Clutch damper spring seat “8” ET1D71021
• Clutch boss “9” REMOVING THE LEFT BALANCER DRIVE
TIP GEAR
There is a built-in damper between the clutch 1. Loosen:
boss and the clutch plate. It is not necessary to • Left balancer drive gear bolt “1”
remove the wire circlip “4” and disassemble the TIP
built-in damper unless there is serious clutch While the holding the generator rotor “2” with the
chattering. primary sheave holder “3”, loosen the left bal-
ancer drive gear bolt.
9
8 Sheave holder
7
6 90890-01701
5 Primary clutch holder
4 YS-01880-A
3
2
1
EAS25090
REMOVING THE PRIMARY DRIVE GEAR

1. Loosen:
• Primary drive gear bolt “1”
5-64
CLUTCH
3
2
EAS25100 B C
CHECKING THE FRICTION PLATES
The following procedure applies to all of the fric-
tion plates.
1. Check:
• Friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
A. Friction plate 1
Out of specification → Replace the friction
B. Friction plate 2
plates as a set.
C. Friction plate 3
TIP
Measure the friction plate at four places. EAS25110
CHECKING THE CLUTCH PLATES

Friction plate 3 thickness clutch plates.
2.90–3.10 mm (0.114–0.122 in)
1. Check:
Wear limit
2.80 mm (0.1102 in) • Clutch plate
Friction plate 1, 2 thickness Damage → Replace the clutch plates as a
2.92–3.08 mm (0.115–0.121 in) set.
Wear limit 2. Measure:
2.82 mm (0.1110 in) • Clutch plate warpage
(with a surface plate and thickness gauge “1”)
Out of specification → Replace the clutch
plates as a set.
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
5-65
CLUTCH
Clutch plate 1 thickness a

2.50–2.70 mm (0.098–0.106 in)
Clutch plate 2, 3 thickness
1.90–2.10 mm (0.075–0.083 in)
Clutch plate 4 thickness
1.90–2.10 mm (0.075–0.083 in)
Warpage limit
0.20 mm (0.0079 in)
TIP
The clutch plate 2, 3 thickness specification list- ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
ed above is for the plates with the standard thick- a. Adjust the total width by replacing the clutch
ness only. If a clutch plate with one of the other plates “1” and “2”.
two plate thicknesses is installed, use 1.50–1.70 b. Select the clutch plate from the following ta-
mm (0.059–0.067 in) or 2.50–2.70 mm (0.098– ble.
0.106 in) for the specification according to the Clutch plate “1” and “2”
plate.
Part No. Thickness
47X-16324-00 1.6 mm (0.063 in)
2H7-16325-00 2.0 mm (0.079 in) STD
2H7-16324-00 2.6 mm (0.102 in)
2 1
3. Measure:
• Assembly width “a”
Out of specification → Adjust.
Assembly width
48.0–48.8 mm (1.89–1.92 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS25140
TIP
CHECKING THE CLUTCH SPRINGS
• This step should be performed only if the fric- The following procedure applies to all of the
tion plates and clutch plates were replaced. clutch springs.
• To measure the assembly width, combine 10 1. Check:
friction plates and 9 clutch plates as shown. • Clutch spring
• When measuring the assembly width, the in- Damage → Replace the clutch springs as a
nermost clutch plate 4 “1” and friction plate 3 set.
“2” are not included. 2. Measure:
• Clutch spring free length “a”
Out of specification → Replace the clutch
2 a
springs as a set.
1
Clutch spring free length
48.48 mm (1.91 in)
Limit
46.06 mm (1.81 in)
5-66
CLUTCH
EAS25170
CHECKING THE PRESSURE PLATE

1. Check:
• Pressure plate
• Bearing
EAS25190
CHECKING THE CLUTCH PUSH RODS

1. Check:
EAS25150
• O-ring
CHECKING THE CLUTCH HOUSING • Short clutch push rod
1. Check: • Long clutch push rod
• Clutch housing dogs • Ball
Damage/pitting/wear → Deburr the clutch Cracks/damage/wear → Replace the defec-
housing dogs or replace the clutch housing. tive part(s).
TIP 2. Measure:
Pitting on the clutch housing dogs will cause er- • Long clutch push rod bending limit
ratic clutch operation. Out of specification → Replace the defective
part(s).
Long clutch push rod bending

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

1. Check:
• Primary drive gear
Damage/wear → Replace the primary drive
and primary driven gears as a set.
2. Check: Excessive noise during operation → Replace
• Bearing the primary drive and primary driven gears as
Damage/wear → Replace the bearing and a set.
clutch housing.
EAS25210
EAS25160
CHECKING THE PRIMARY DRIVEN GEAR
CHECKING THE CLUTCH BOSS 1. Check:
1. Check: • Primary driven gear “1”
• Clutch boss splines Damage/wear → Replace the primary drive
Damage/pitting/wear → Replace the clutch and primary driven gears as a set.
boss. Excessive noise during operation → Replace
TIP the primary drive and primary driven gears as
Pitting on the clutch boss splines will cause er- a set.
ratic clutch operation.
5-67
CLUTCH
ET1D71033
4. Calculate:
CHECKING THE LEFT BALANCER GEARS
• Left-balancer-driven-gear-to-left-balancer-
1. Check:
driven-gear-housing clearance
• Left balancer drive gear
Out of specification → Replace the defective
• Left balancer driven gear
part(s).
• Left balancer idle gear
Burrs/chips/roughness/wear → Replace the TIP
defective part(s). Calculate the clearance by subtracting the left
2. Measure: balancer driven gear housing outside diameter
• Left balancer driven gear inside diameter “a” from the left balancer driven gear inside diame-
Out of specification → Replace. ter.
Left balancer driven gear inside Left-balancer-driven-gear-to-left-

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

GEAR
1. Install:
• Left balancer weight 1 “1”
• Left balancer weight 2 “2”
• Left balancer driven gear “3”
TIP
Make sure that the punch marks “a” on the left
balancer driven gear are facing toward left bal-
ancer weight 2.
3. Measure:
• Left balancer driven gear housing outside di-
ameter “a” Left balancer weight bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
LOCTITE®
Left balancer driven gear hous-
ing outside diameter “a”
58.925–58.960 mm (2.320–2.321 3
in)
Limit 2
58.900 mm (2.318 in) a
2. Remove:
• Generator rotor
Refer to “REMOVING THE GENERATOR”
on page 5-80.
3. Align:
• Mark “a” on the generator drive gear of the
crankshaft
(with the mark “b” on the generator shaft driv-
en gear)
5-68
CLUTCH
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft. Sheave holder
b. When the front and rear pistons are near 90890-01701
TDC, align the mark “a” on the generator Primary clutch holder
drive gear of the crankshaft with the mark “b” YS-01880-A
on the generator shaft driven gear.
b a
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Generator rotor
Refer to “INSTALLING THE GENERATOR”
on page 5-81.
5. Install:
• Left balancer drive gear “1”
• Left balancer idle gear “2” 3
• Left balancer driven gear “3” 2
TIP
EAS25230
• Align the punch mark “a” on the left balancer INSTALLING THE PRIMARY DRIVE GEAR
drive gear with the punch mark “b” on the left 1. Install:
balancer idle gear. • Washer
• Align the punch marks “c” on the left balancer • Straight key
idle gear with the punch marks “d” on the left • Primary drive gear
balancer driven gear. • Crankshaft position sensor rotor “1”
• Spacer
d • Primary drive gear bolt “2”
c 3
Primary drive gear bolt
100 Nm (10.0 m·kg, 72 ft·lb)
T.
R.
EC1D71007
1 NOTICE
a The timing marks on the crankshaft position
b 2 sensor rotor must face outside.
6. Tighten: TIP
• Left balancer drive gear bolt “1” • Lubricate the primary drive gear bolt threads
with engine oil.
Left balancer drive gear bolt • While holding the generator rotor “3” with the
40 Nm (4.0 m·kg, 29 ft·lb) sheave holder “4”, tighten the primary drive
T.
R.
gear bolt.
TIP
While holding the generator rotor “2” with the
sheave holder “3”, tighten the left balancer drive
gear bolt.
5-69
CLUTCH
• If the wire circlip “6” has been removed, care-

Sheave holder fully install a new one.
90890-01701
YS-01880-A 1
2
4
5
3
1
New 6
2 3. Install:
• Clutch boss “1”
• Washer
• Clutch boss nut “3” New
Clutch boss nut

105 Nm (10.5 m·kg, 75 ft·lb)
T.
R.
TIP
4 • Lubricate the clutch boss nut threads and con-
3 ical spring washer mating surfaces with engine
oil.
EAS25260
INSTALLING THE CLUTCH “OUT” mark “a” facing out.
1. Install: • While holding the clutch boss with the univer-
• Clutch housing sal clutch holder “4”, tighten the clutch boss
• Thrust washer 1 nut.
TIP • Stake the clutch boss nut “3” at a cutout “b” in
• Lubricate the clutch housing bearings with en- the main axle.
gine oil.
• Make sure that the primary driven gear teeth Universal clutch holder
and primary drive gear teeth mesh correctly. 90890-04086
• Make sure that the primary driven gear teeth YM-91042
and oil pump driven gear teeth mesh correctly.
2. Install: 1 2
4
• Clutch boss “1”
• Clutch damper spring seat “2”
• Clutch damper spring “3” a
• Friction plate 3 “4”
• Clutch plate 4 “5”
• Wire circlip “6” New b
New 3
TIP
• Install the clutch damper spring “3” with the
“OUTSIDE” mark facing out. 4. Lubricate:
• Install clutch plate 4 “5” with its rounded side • Friction plates
facing outward. • Clutch plates
5-70
CLUTCH
8. Install:
Recommended lubricant • Shift arm “1”
Engine oil
Shift arm bolt
5. Install: 12 Nm (1.2 m·kg, 8.7 ft·lb)
T.
R.
• Friction plates
• Clutch plates TIP
TIP Install the shift arm “1” with its slot “a” aligned
• First, install a friction plate and then alternate with the mark “b” in end of the shift shaft.
between a clutch plate and a friction plate.
• Align the cutout in the tab of each friction plate
2 and the first friction plate 1 “1” with the “ ”
mark “a” on the clutch housing.
• Align the cutout in the tab of the last friction
plate 1 “2” with the punch mark “b” on the
clutch housing.
1
b a b
a
a
EAS25280
1 DISASSEMBLING THE CLUTCH MASTER

CYLINDER
b
TIP
2 Before disassembling the clutch master cylinder,
drain the clutch fluid from the entire clutch sys-
tem.
6. Install: 1. Remove:
• Clutch spring • Clutch hose union bolt “1”
• Clutch spring retainer • Copper washers “2”
Clutch spring retainer bolt • Clutch hose “3”
10 Nm (1.0 m·kg, 7.2 ft·lb) TIP
T.
R.
To collect any remaining clutch fluid, place a

7. Apply: container under the master cylinder and the end
• Sealant of the clutch hose.
(onto the crankshaft position sensor lead
grommet)
Yamaha bond No. 1215

90890-85505
(Three Bond No.1215®) 2
3
ET1D71037
CHECKING THE CLUTCH MASTER

CYLINDER
1. Check:
• Clutch master cylinder
Damage/scratches/wear → Replace.
5-71
CLUTCH
• Clutch fluid delivery passage 2. Install:

(clutch master cylinder body) • Copper washers New
Obstruction → Blow out with compressed air. • Clutch hose “1”
2. Check: • Clutch hose union bolt “2”
• Clutch master cylinder kit
Damage/scratches/wear → Replace. Clutch hose union bolt
3. Check: 30 Nm (3.0 m·kg, 22 ft·lb)
T.
R.
• Clutch master cylinder reservoir
EWA1D77010
WARNING
• Clutch master cylinder reservoir diaphragm
Damage/wear → Replace. Proper clutch hose routing is essential to in-
4. Check: sure safe vehicle operation. Refer to “CABLE
• Clutch hose ROUTING (for XV19S(C)/ XV19CTS(C))” on
Cracks/damage/wear → Replace. page 2-49 and “CABLE ROUTING (for
EAS25300
ASSEMBLING THE CLUTCH MASTER TIP

CYLINDER • Install the clutch hose at a right angle to the
EW1D71010
clutch master cylinder as shown in the illustra-
WARNING
tion.
• Before installation, all internal clutch com- • While holding the clutch hose, tighten the
ponents must be cleaned and lubricated union bolt.
with clean or new clutch fluid. • Turn the handlebar to the left and right to make
• Never use solvents on internal clutch com- sure the clutch hose does not touch other parts
ponents. (e.g., wire harness, cables, leads). Correct if
necessary.
Brake fluid DOT 4 A
EAS25310
INSTALLING THE CLUTCH MASTER

CYLINDER
1. Install:
1
• Clutch master cylinder “1” 2
• Clutch master cylinder holder “2”
5–25˚
Clutch master cylinder holder
bolt B
T.
R.
10 Nm (1.0 m·kg, 7.2 ft·lb)
TIP
• Align the end of the clutch lever holder with the
punch mark “a” on the handlebar.
• First, tighten the rear bolt, then the front bolt.
1 15–35˚

3. Fill:
• Clutch master cylinder reservoir
a mended clutch fluid)
2
5-72
CLUTCH

Recommended clutch fluid CLUTCH SYSTEM” on page 3-15.
Brake fluid DOT 4
ET1D71004
EWA13370 REMOVING THE CLUTCH RELEASE

WARNING CYLINDER
• Use only the designated clutch fluid. Other 1. Remove:
clutch fluids may cause the rubber seals to • Clutch pipe union bolt “1”
deteriorate, causing leakage and poor • Copper washers “2”
clutch performance. • Clutch pipe “3”
• Refill with the same type of clutch fluid that TIP
is already in the system. Mixing clutch flu- Put the end of the clutch pipe into a container
ids may result in a harmful chemical reac- and pump out the clutch fluid carefully.
tion, leading to poor clutch performance.
not enter the clutch fluid reservoir. Water
ECA13420
1
NOTICE
Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
2 3
spilt clutch fluid immediately.
TIP EAS25330
In order to ensure a correct reading of the clutch CHECKING THE CLUTCH RELEASE
fluid level, make sure the top of the reservoir is CYLINDER
horizontal. Recommended clutch component replace-
ment schedule
4. Bleed:
• Clutch system Piston seal Every two years
Refer to “BLEEDING THE HYDRAULIC Clutch hose Every four years
5. Check: Every two years and
Clutch fluid whenever the clutch
• Clutch fluid level
is disassembled
recommended clutch fluid to the proper level. 1. Install:
Refer to “CHECKING THE CLUTCH FLUID • Clutch release cylinder body
LEVEL” on page 3-14. Cracks/damage → Replace the clutch re-
lease cylinder.
2. Check:
• Clutch release cylinder “1”
• Clutch release cylinder piston “2”
Rust/scratches/wear → Replace the clutch
release cylinder and clutch release cylinder
piston as a set.
6. Check:
• Clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
5-73
CLUTCH
2 2
1
b
EAS25340 2. Fill:
ASSEMBLING THE CLUTCH RELEASE • Clutch master cylinder reservoir
CYLINDER (with the specified amount of the recom-
EW1D71006
mended clutch fluid)
WARNING
• Before installation, all internal clutch com- Recommended clutch fluid
ponents must be cleaned and lubricated Brake fluid DOT 4
with clean or new clutch fluid.
EWA13370
• Never use solvents on internal clutch com- WARNING
ponents as they will cause the piston seal
to swell and distort. • Use only the designated clutch fluid. Other
• Whenever a clutch release cylinder is dis- clutch fluids may cause the rubber seals to
assembled, replace the piston seal. deteriorate, causing leakage and poor
clutch performance.
• Refill with the same type of clutch fluid that
is already in the system. Mixing clutch flu-
Brake fluid DOT 4
ids may result in a harmful chemical reac-
EAS25350
tion, leading to poor clutch performance.
INSTALLING THE CLUTCH RELEASE • When refilling, be careful that water does
CYLINDER not enter the clutch fluid reservoir. Water
1. Install: will significantly lower the boiling point of
• Copper washers New
ECA13420
• Clutch pipe “1”
NOTICE
• Clutch pipe union bolt “2”
Clutch fluid may damage painted surfaces or
Clutch pipe union bolt plastic parts. Therefore, always clean up any
26 Nm (2.6 m·kg, 19 ft·lb) spilt clutch fluid immediately.
T.
R.
EWA1D77009 TIP
WARNING In order to ensure a correct reading of the clutch
Proper clutch pipe routing is essential to in- fluid level, make sure that the top of the reservoir
sure safe vehicle operation. Refer to “CABLE is horizontal.
page 2-49 and “CABLE ROUTING (for 3. Bleed:
XV19CS(C)/ XV19C(C))” on page 2-67. • Clutch system
EC1D71005
NOTICE
4. Check:
When installing the clutch pipe onto the • Clutch fluid level
clutch release cylinder, make sure the pipe Below the minimum level mark “a” → Add the
“a” touches the projection “b” on the clutch recommended clutch fluid to the proper level.
release cylinder. Refer to “CHECKING THE CLUTCH FLUID
5-74
CLUTCH
5. Check:
• Clutch lever operation
Soft or spongy feeling → Bleed the clutch
system.
5-75
SHIFT SHAFT
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
LT
New
LS
1
2
1
4
7 3
E
New 2
1
6
5
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Clutch housing Refer to “CLUTCH” on page 5-53.
1 Washer 3
2 Circlip 2
3 Shift shaft 1
4 Shift shaft spring 1
5 Stopper lever 1
6 Collar 1
7 Stopper lever spring 1
8 Shift shaft spring stopper 1
dure.
5-76
SHIFT SHAFT
EAS25420
CHECKING THE SHIFT SHAFT

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

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

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

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
LOCTITE®
TIP
• Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss “4”.
• Mesh the stopper lever with the shift drum seg-
ment assembly.
4
3
2
2. Install:
• Washers
• Circlips
• Shift shaft spring “1”
• Shift shaft “2”
TIP
Hook the end of the shift shaft spring onto the
shift shaft spring stopper “3”.
5-77
GENERATOR AND STARTER CLUTCH
EAS24480

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

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

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

T.
T.
R.
R.

Drain.
page 3-11.
Lead cover Refer to “BELT DRIVE” on page 4-90.
Clutch pipe Refer to “CLUTCH” on page 5-53.
1 Stator coil coupler 1 Disconnect.
3 Generator cover 1
4 Generator cover gasket 1
5 Dowel pin 2
6 Stator coil lead holder 1
7 Stator coil 1
dure.
5-78
Removing the generator rotor
7
9
24 Nm (2.4 m • kg, 17 ft • Ib)

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

T.
R.
80 Nm (8.0 m • kg, 58 ft • Ib)

.
T
R.

1 Torque limiter 1
2 Starter clutch idle gear shaft 1
3 Starter clutch idle gear 1
4 Generator rotor 1
5 Starter clutch 1
6 Woodruff key 1
7 Starter clutch gear 1
8 Bearing 1
9 Bearing housing 1
dure.
5-79
EAS24490
REMOVING THE GENERATOR TIP

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

3 1. Check:
1 2 • Starter clutch rollers
2. Remove: 2. Check:
• Generator rotor “1” • Starter clutch idle gear
(with the rotor puller “2”) • Starter clutch gear
• Woodruff key Burrs/chips/roughness/wear → Replace the
Rotor puller defective part(s).
90890-01080 3. Check:
Stator rotor puller • Starter clutch gear’s contacting surfaces
YM-01080-A Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear “1” onto the
starter clutch and hold the generator rotor “2”.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
clutch gear should engage, otherwise the
2 1 starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counter-
EAS24560
clockwise “B”, it should turn freely, otherwise
REMOVING THE STARTER CLUTCH the starter clutch is faulty and must be re-
1. Remove: placed.
• Starter clutch bolts
• Starter clutch
5-80
• Washer
• Generator rotor bolt “2”
TIP
• Clean the tapered portion of the generator
shaft and the generator rotor hub.
• When installing the rotor, make sure the woo-
druff key is properly seated in the key way of
the generator shaft.
• Lubricate the generator rotor bolt threads and
washer mating surfaces with engine oil.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71020
CHECKING THE TORQUE LIMITER

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

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

T.
R.
LOCTITE® TIP
While holding the generator rotor “2” with a
TIP
sheave holder “3”, tighten the generator rotor
While holding the generator rotor “1” with the bolt.
sheave holder “2”, tighten the starter clutch
bolts.
Sheave holder
90890-01701
Sheave holder Primary clutch holder
90890-01701 YS-01880-A
YS-01880-A
3
1 2 1 2
3. Apply:
• Sealant
EAS24510
(onto the stator coil lead grommet)
INSTALLING THE GENERATOR
1. Install: Yamaha bond No. 1215
• Woodruff key 90890-85505
• Generator rotor “1” (Three Bond No.1215®)
5-81
5-82
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

1 Starter motor lead 1 Disconnect.
2 Starter motor 1
dure.
5-83
ELECTRIC STARTER
Disassembling the starter motor
LS
LS
New
1 New 3 2
New 4
10 New
New
11
12
7
6
8
New 10 9

1 Starter motor front cover 1
2 Bearing 1
3 Oil seal 1
4 Circlip 1
5 Starter motor rear cover 1
6 Brush 2
7 Brush holder (along with the brushes) 1
8 Brush seat (along with the brushes) 1
9 Bearing 1
10 Gasket 2
11 Armature assembly 1
12 Starter motor yoke 1
cedure.
5-84
ELECTRIC STARTER
EAS24790
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE STARTER MOTOR a. Measure the armature assembly resistances
1. Check: with the pocket tester.
• Commutator
Dirt → Clean with 600 grit sandpaper. Pocket tester
2. Measure: 90890-03112
• Commutator diameter “a” Analog pocket tester
Out of specification → Replace the starter YU-03112-C
motor.
Limit Armature coil

XV19S(C)/ XV19CTS(C): Commutator resistance “1”
27.0 mm (1.06 in) 0.0081–0.0099 Ω at 20 °C (68 °F)
XV19CS(C)/ XV19C(C): Insulation resistance “2”
27.5 mm (1.08 in) Above 1 MΩ at 20 °C (68 °F)
3. Measure: b. If any resistance is out of specification, re-

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

that has been grounded to fit the commutator. • Brush length “a”
Out of specification → Replace the brushes
Mica undercut (depth) as a set.
1.50 mm (0.06 in)
Limit
TIP 7.60 mm (0.30 in)
The mica of the commutator must be undercut to
ensure proper operation of the commutator.
6. Measure:
• Brush spring force
4. Measure: Out of specification → Replace the brush
• Armature assembly resistances (commutator springs as a set.
and insulation)
Out of specification → Replace the starter Brush spring force
motor. 7.36–11.04 N (26.49–39.74 oz)
(750–1126 gf)
5-85
ELECTRIC STARTER
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearings
• Oil seal
Damage/wear → Replace the defective
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke “1”
TIP
Align the projection “a” on the brush holder with
the slot “b” in the starter motor yoke.
1 b
a
2. Install:
• Starter motor front cover “1”
TIP
Align the match mark “a” on the starter motor
yoke with the match mark “b” on the starter mo-
tor front cover.
a b
5-86
TRANSFER GEAR CASE
EAS25460
TRANSFER GEAR CASE

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

T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)

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

T.
T.
R.
R.

Rider seat/Right side cover 4-1.
Drain.
page 3-11.
Drain.
Clutch release cylinder Refer to “CLUTCH” on page 5-53.
1 Oil pipe 2 1
2 Oil pipe 4 1
3 Transfer gear case cover 1
4 Transfer gear case gasket 1
5 Dowel pin 2
6 Transfer gear oil pump assembly 1
7 Dowel pin 2
5-87
TRANSFER GEAR CASE
Removing the middle driven shaft

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

T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)

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

T.
T.
R.
R.

8 Oil strainer 1
9 Gasket 1
11 Primary chain 1
12 Middle drive gear 1
13 Middle driven shaft 1
dure.
5-88
TRANSFER GEAR CASE
Disassembling the transfer gear oil pump
4
5
7
E 3
2
1
(6)
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.
R.

1 Transfer gear oil pump cover 1
2 Transfer gear oil pump outer rotor 1
3 Transfer gear oil pump inner rotor 1
4 Pin 1
5 Washer 1
6 Transfer gear oil pump shaft 1
7 Transfer gear oil pump housing 1
cedure.
5-89
TRANSFER GEAR CASE
Removing the transfer gear case

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

Disconnect.
Horn 2 coupler Refer to “ENGINE REMOVAL” on page 5-1.
Battery box 4-1.
Sub-fuel tank Refer to “FUEL TANK” on page 6-1.
1 Oil tank breather hose 1 Disconnect.
2 Speed sensor 1
3 Oil tank damper 1
4 Dipstick 1
5 Dipstick joint 1
6 Drive pulley case 1
7 Dowel pin 2
8 Spacer 1
9 Transfer gear case 1
10 Dowel pin 2
dure.
5-90
TRANSFER GEAR CASE
Disassembling the oil tank
7 28 Nm (2.8 m • kg, 20 ft • Ib)
T.
R.
4
6
1
New
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LS
LT
LT
New
New
5
(15)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
43 Nm (4.3 m • kg, 31 ft • Ib)

T.
R.
3 New

1 Sub-fuel tank bracket 1
2 Oil tank cover 1
3 Oil tank cover gasket 1
4 Dowel pin 2
5 Oil strainer 1
6 Oil pipe 5 1
7 Oil tank 1
cedure.
5-91
TRANSFER GEAR CASE
EAS25470
2. Check:
REMOVING THE MIDDLE DRIVEN SHAFT
• Primary chain
TIP Damage/stiffness → Replace the primary
Loosen the middle drive gear nut before remove chain, middle drive gear and middle driven
the drive pulley. shaft as a set.
1. Install: EAS25490
• Right rider footrest assembly CHECKING THE OIL STRAINER

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

1. Check:
• Middle drive gear
• Middle driven gear
Damage/wear → Replace the middle drive
gear, middle driven shaft and primary chain 1. Transfer gear oil pump inner rotor
as a set. 2. Transfer gear oil pump outer rotor
3. Transfer gear oil pump housing
5-92
TRANSFER GEAR CASE
• Transfer gear oil pump cover “7”

Inner-rotor-to-outer-rotor-tip TIP
clearance
Less than 0.12 mm (0.0047 in) When installing the inner rotor, align the pin in
Limit the oil pump shaft with the groove in the inner ro-
0.20 mm (0.0079 in) tor.
Outer-rotor-to-oil-pump-housing
clearance Oil pump housing screw
0.10–0.15 mm (0.0039–0.0059 in) 4 Nm (0.4 m·kg, 2.9 ft·lb)
T.
Limit
R.
0.22 mm (0.0087 in)
Oil-pump-housing-to-inner-and- 1
outer-rotor clearance 4
0.04–0.09 mm (0.0016–0.0035 in) E
3
Limit 5 2
0.160 mm (0.0063 in) 6
7
3. Check:
• Transfer gear oil pump operation
Rough movement → Repeat steps (1) and (6)
(2) or replace the defective part(s).
3. Check:
• Transfer gear oil pump operation
Refer to “CHECKING THE TRANSFER
GEAR OIL PUMP” on page 5-92.
EAS25530
INSTALLING THE TRANSFER GEAR CASE

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

PUMP
1. Lubricate:
• Transfer gear oil pump inner rotor
• Transfer gear oil pump outer rotor a
• Transfer gear oil pump shaft
(with the recommended lubricant) 2. Install:
• Middle driven shaft “1”
Recommended lubricant • Middle drive gear “2”
Engine oil • Primary chain “3”
(into the transfer gear case)
2. Install: • Drive pulley nut
• Transfer gear oil pump shaft “1” TIP
(to the transfer gear oil pump housing “2”)
• Install the primary chain with its blue link “a”
• Washer “3”
facing outward.
• Pin “4”
• Install the middle drive gear “2” with its cham-
• Transfer gear oil pump inner rotor “5”
fered side facing “b” the transfer gear case.
• Transfer gear oil pump outer rotor “6”
5-93
TRANSFER GEAR CASE
• Install the middle driven shaft, middle drive 4. Remove:

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

140 Nm (14.0 m·kg, 100 ft·lb)
T.
R.
TIP
• Lubricate the middle drive gear nut threads
and conical spring washer mating surfaces
with engine oil.
“OUT” mark “a” facing out.
• Stake the middle drive gear nut “2” at a cutout
“b” in the drive axle.
a
2 New
5-94
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T.
LT
R. LT
LS 1 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New
New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(5) LS
T.
(4)
R.
LT
LT
New
3 9
3 (4) (4)
11
LS
(8)
LS
12
13 LT
4
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
9 New
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 5
T.
R.
New 6
7
8 (6)
LS New New LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Camshafts Refer to “CAMSHAFTS” on page 5-17.
Refer to “CYLINDERS AND PISTONS” on
Pistons page 5-48.
Left balancer driven gear housing Refer to “CLUTCH” on page 5-53.
Shift shaft Refer to “SHIFT SHAFT” on page 5-76.
Refer to “GENERATOR AND STARTER
Generator rotor CLUTCH” on page 5-78.
1 Neutral switch 1
2 Oil pipe 3 1
3 Oil strainer 2
5 Engine oil pump driven gear stopper 1
6 Engine oil pump driven gear 1
7 Oil baffle plate (left crankcase) 1
8 Left crankcase 1
9 Dowel pin 2
5-95
CRANKCASE
Separating the crankcase

10 Nm (1.0 m • kg, 7.2 ft • Ib)
LT
T.
LT
R.
LT
LS 1 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
New
New 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
(5) LS
T.
(4)
R.
LT
LT
New
3 9
3 (4) (4)
11
LS
(8)
LS
12
13 LT
4
24 Nm (2.4 m • kg, 17 ft • Ib)
T.
R.
9 New
10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 5
T.
R.
New 6
7
8 (6)
LS New New LT
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
32 Nm (3.2 m • kg, 23 ft • Ib)

T.R
.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

10 Joint pipe 1
11 Oil pipe 1 “R” mark
12 Oil pipe 1 “F” mark
13 Right crankcase 1
dure.
5-96
CRANKCASE
Removing the oil seals and bearings
LS
New 4
LS
5
E
LT
LT
New
2
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
5
New
1
LT
5
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)

3
T.
R.
LT
12 Nm (1.2 m • kg, 8.7 ft • Ib)

5
3
T.R
.
E
LT

Oil pump Refer to “OIL PUMP” on page 5-101.
Crankshaft Refer to “CRANKSHAFT” on page 5-107.
Transmission Refer to “TRANSMISSION” on page 5-113.
1 Oil baffle plate (right crankcase) 1
2 Bearing retainer 2
3 Bearing retainer 2
4 Oil seal 2
5 Bearing 4
dure.
5-97
CRANKCASE
EAS25570
DISASSEMBLING THE CRANKCASE

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

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

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

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

ECA13900 1. Check:
NOTICE • Oil strainers
Tap on one side of the crankcase with a soft- Damage → Replace.
face hammer. Tap only on reinforced por- Contaminants → Clean with solvent.
tions of the crankcase, not on the crankcase EAS25610
mating surfaces. Work slowly and carefully CHECKING THE ENGINE OIL PUMP DRIVEN
and make sure the crankcase halves sepa- GEAR
rate evenly. 1. Check:
• Engine oil pump driven gear
Chips/pitting/roughness/wear → Replace.
5-98
CRANKCASE
ET1D71034
INSTALLING THE BEARING RETAINERS 1

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

Separate.
Crankcase Refer to “CRANKCASE” on page 5-95.
1 Oil pump assembly 1
dure.
5-101
OIL PUMP
Disassembling the oil pump
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
3
2
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
E
12
15
16
18 17
11
4
19 New
24
E
7
10 E
New 20
22 9
New 21 23
13
14 7
8

1 Oil pump housing cover 1 1
2 Oil scavenging pump outer rotor 1 1
3 Oil scavenging pump inner rotor 1 1
4 Pin 1
5 Oil pump housing 1 1
6 Oil strainer 1
7 Pin 2
8 Ball spring 1
9 Oil scavenging pump outer rotor 2 1
10 Oil scavenging pump inner rotor 2 1
11 Pin 1
12 Oil pump housing cover 2 1
13 Relief valve spring 1
14 Relief valve 1
15 Oil feed pump outer rotor 1
16 Oil feed pump inner rotor 1
17 Pin 1
5-102
OIL PUMP
Disassembling the oil pump
5
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
3
2
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
E
12
15
16
18 17
11
4
19 New
24
E
7
10 E
New 20
22 9
New 21 23
13
14 7
8

18 Oil pump shaft 1
19 Oil seal 1
20 Circlip 1
21 Oil seal 1
22 Ball 1
23 Ball guide 1
24 Oil pump housing 2 1
cedure.
5-103
OIL PUMP
EAS24960
3. Check:
CHECKING THE OIL PUMP
• Oil pump operation
1. Check:
Rough movement → Repeat steps (1) and
• Oil pump housing
(2) or replace the defective part(s).
• Oil pump housing cover
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip EAS24970
clearance CHECKING THE RELIEF VALVE

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

clearance VALVE SPRING
0.09–0.19 mm (0.0035–0.0075 in) 1. Measure:
Limit • Ball spring free length
0.26 mm (0.0102 in) • Relief valve spring free length
Out of specification → Replace the defective
part(s).
Ball spring
Free length
34.70 mm (1.37 in)
Limit
32.97 mm (1.30 in)
Relief valve spring
Free length
28.95 mm (1.14 in)
Limit
27.50 mm (1.08 in)
1. Inner rotor
2. Outer rotor a. Free length
3. Oil pump housing
5-104
OIL PUMP
2. Measure: • Oil pump shaft

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

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

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

1. Lubricate:
• Inner rotor
• Outer rotor
5-105
OIL PUMP
20
22
23
24
19
13 E
10
9
78
14 21
6 New
1
E 18 E
15
New 5 16
3 2
New 4
12
11 18
17
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-104.
EAS25020
INSTALLING THE OIL PUMP

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

24 Nm (2.4 m·kg, 17 ft·lb)
T.
R.
ECA13890
NOTICE
After tightening the bolts, make sure the oil
pump turns smoothly.
5-106
CRANKSHAFT
EAS25960
CRANKSHAFT
Removing the crankshaft

Separate.
1 Crankshaft 1
2 Generator shaft 1
3 Connecting rod cap 2
4 Big end lower bearing 2
5 Connecting rod 2
6 Big end upper bearing 2
dure.
5-107
CRANKSHAFT
EAS26010
REMOVING THE CONNECTING RODS

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

tigauge®)
0.030–0.060 mm (0.0012–0.0024
in)
EAS26090 The following procedure applies to all of the

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

shaft pin.
5-108
CRANKSHAFT
d. Assemble the connecting rod halves. h. Tighten the connecting rod bolts further to
TIP reach the specified angle 125–135°.
• Do not move the connecting rod or crankshaft
Connecting rod bolt (final)
until the clearance measurement has been Specified angle 125–135°
T.
completed.
R.
• Lubricate the bolts threads with molybdenum
disulfide grease.
• Make sure the projection “c” on the connecting
rod faces towards the left side of the crank-
shaft.
• Make sure the characters “d” on both the con-
necting rod and connecting rod cap are
aligned.
EW1D71011
WARNING
When a bolt is tightened more than the spec-
ified angle, do not loosen and then retighten
it.
Replace the bolt with a new one and perform
the procedure again.
EC1D71001
e. Tighten the connecting rod bolts. NOTICE

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

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

and the connecting rod cap “3”.
5-109
CRANKSHAFT
For example, if the connecting rod “P1” and

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

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

diameter
50.010–50.030 mm (1.9689–
1.9697 in)
5-110
CRANKSHAFT
EAS26150
INSTALLING THE CONNECTING RODS

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

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

rod bolts “2” and the connecting rod “3”.
5-111
CRANKSHAFT
TIP
• Make sure that the generator shaft drive gear
teeth and generator shaft driven gear teeth
mesh correctly.
• Align the punch mark “a” on the generator shaft
driven gear with the punch mark “b” on the gen-
erator shaft drive gear.
• Align the right connecting rod with the front cyl-
inder sleeve hole.
c. Tighten the connecting rod bolts further to
reach the specified angle 125–135°.
Connecting rod bolt (final)

Specified angle 125–135°
T.
R.
2 b a
EW1D71011
WARNING
When a bolt is tightened more than the spec-
ified angle, do not loosen and then retighten
it.
Replace the bolt with a new one and perform
the procedure again.
EC1D71001
NOTICE
• Do not use a torque wrench to tighten the
bolt to the specified angle.
• Tighten the bolt until it is at the specified
angle.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS26210
INSTALLING THE CRANKSHAFT

ASSEMBLY
1. Install:
• Generator shaft “1”
• Crankshaft assembly “2”
ECA13970
NOTICE
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
5-112
TRANSMISSION
EAS26240
TRANSMISSION
Removing the transmission, shift drum assembly, and shift forks
New
LS E
2
7
3
1
3
M
E
4
E
1
M
6

Separate.
1 Shift fork guide bar 2
2 Shift drum assembly 1
3 Shift fork 1 2
4 Shift fork 2 1
5 Drive axle assembly 1
6 Main axle assembly 1
7 Spacer 1
dure.
5-113
TRANSMISSION
Disassembling the main axle assembly

1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 5th pinion gear 1
5 Collar 1
6 Toothed washer 1
7 Circlip 1
8 3rd pinion gear 1
9 Circlip 1
10 Toothed washer 1
11 4th pinion gear 1
12 Collar 1
13 Main axle/1st pinion gear 1
cedure.
5-114
TRANSMISSION
Disassembling the drive axle assembly

1 Circlip 1
2 Washer 1
3 1st wheel gear 1
4 Collar 1
5 4th wheel gear 1
6 Circlip 1
7 Toothed washer 1
8 3rd wheel gear 1
9 Collar 1
10 Toothed lock washer 1
11 Toothed lock washer retainer 1
12 5th wheel gear 1
13 Circlip 1
14 Toothed washer 1
15 2nd wheel gear 1
16 Collar 1
5-115
TRANSMISSION
Disassembling the drive axle assembly

17 Drive axle 1
cedure.
5-116
TRANSMISSION
EAS26260 EAS26270
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY

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

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

0.08 mm (0.0032 in)
5-117
TRANSMISSION
1 2
2 New
3. Check:
• Transmission gears b
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
2. Install:
• Toothed lock washer retainer “1”
• Toothed lock washer “2”
TIP
• With the toothed lock washer retainer “1” in the
groove “a” in the axle, align the projection “c”
4. Check: on the retainer with an axle spline “b”, and then
• Transmission gear engagement install the toothed lock washer “2”.
(each pinion gear to its respective wheel • Be sure to align the projection on the toothed
gear) lock washer that is between the alignment
Incorrect → Reassemble the transmission marks “e” with the alignment mark “d” on the
axle assemblies. retainer.
5. Check:
• Transmission gear movement 1 d b e
2
Rough movement → Replace the defective c
part(s). b
6. Check:
• Circlips a
Bends/damage/looseness → Replace. c
2
ET1D71006
ASSEMBLING THE MAIN AXLE AND DRIVE 1 e

AXLE
1. Install: EAS26320
• Toothed washer “1” INSTALLING THE SHIFT FORKS AND SHIFT

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

REMOVING THE FUEL TANK ..................................................................6-3
REMOVING THE FUEL PUMP .................................................................6-3
CHECKING THE FUEL PUMP BODY.......................................................6-4
CHECKING THE FUEL PUMP OPERATION............................................6-4
INSTALLING THE FUEL PUMP................................................................6-4
INSTALLING THE FUEL TANK.................................................................6-4
THROTTLE BODIES .......................................................................................6-6

REMOVING THE FUEL HOSE ...............................................................6-14
CHECKING THE INJECTORS ................................................................6-14
CHECKING THE THROTTLE BODIES...................................................6-14
CHECKING THE ROLLOVER VALVES.................................................. 6-14
CHECKING THE PRESSURE REGULATOR .........................................6-14
CHECKING THE PRESSURE REGULATOR OPERATION ................... 6-14
ADJUSTING THE THROTTLE POSITION SENSOR..............................6-15
INSTALLING THE FUEL HOSE ..............................................................6-15
ISC (IDLE SPEED CONTROL) UNIT ............................................................ 6-17

CHECKING THE ISC (IDLE SPEED CONTROL) SYSTEM ................... 6-18
6
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank
3 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
1
7
5
2
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib) 9 10
8
T.
R.
(4) A
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
4
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

Rider seat/Rider seat bracket 4-1.
1 Meter cover 1
Disconnect.
2 Meter assembly coupler 3 For XV19S(C)/ XV19CTS(C)
Disconnect.
3 Meter assembly coupler 2 For XV19CS(C)/ XV19C(C)
4 Fuel sender coupler 1 Disconnect.
5 Fuel tank breather hose 1 Disconnect.
6 Air vent hose (fuel pump to fuel hose joint) 1 Disconnect.
7 Fuel tank 1
8 Fuel tank bracket (rear side) 1
9 Fuel tank bracket (front side) 1
10 Fuel sender 1
dure.
A: For XV19CS(C)/ XV19C(C)
6-1
FUEL TANK
Removing the fuel pump and sub-fuel tank
4
5 Nm (0.5 m • kg, 3.6 ft • Ib)
T.
R.
5
3 New
1
(6)
2 6
7
8 New
(3)
(3)
9
(3)
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.

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

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

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

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

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

sender. When installing the fuel outlet hose, make
sure that it is securely connected, and that
EAS26670
CHECKING THE FUEL PUMP BODY the fuel hose connector cover is installed
1. Check: correctly, otherwise the fuel outlet hose will
• Fuel pump body not be properly installed.
Obstruction → Clean. TIP
Cracks/damage → Replace fuel pump as- • Install the fuel outlet hose connector securely
sembly. onto the sub fuel tank until a distinct “click” is
2. Check: heard, and then make sure that it does not
• Diaphragms and gaskets come loose.
Tears/fatigue/cracks → Replace fuel pump • Install the holder “a” of the fuel hose connector
assembly. cover, and then install the holder “b”. After in-
EAS26690 stalling the fuel hose connector cover, make
CHECKING THE FUEL PUMP OPERATION sure that it is installed securely.
1. Check:
• Fuel pump operation
Refer to “CHECKING THE FUEL PUMP” on 1
page 7-91. a
EAS26710
INSTALLING THE FUEL PUMP

1. Install:
• Fuel pump
Fuel pump bolt b

5 Nm (0.5 m·kg, 3.6 ft·lb)
T.
R.
ET1D71025
TIP
INSTALLING THE FUEL TANK
1. Install:
• Do not damage the installation surfaces of the
• Fuel tank
sub-fuel tank when installing the fuel pump. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Always use a new fuel pump gasket. a. Install the fuel tank.
6-4
FUEL TANK
b. Remove the fuel hose joint caps.

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

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

T.
R.

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

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

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

T.
R.
3 9
4

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

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

R.
T.
R.

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

dure.
6-11
THROTTLE BODIES
Removing the intake manifolds
10 Nm (1.0 m • kg, 7.2 ft • Ib)

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

T.
R.

1 Engine temperature sensor coupler 1 Disconnect.
2 Sub-wire harness 2 coupler 2 Disconnect.
4 1
sure regulator)
Cylinder-#2 ISC (idle speed control) unit outlet
5 1 Disconnect.
hose
6 1 Disconnect.
hose
7 Intake manifold assembly 1
8 Gasket 2
dure.
6-12
THROTTLE BODIES
Disassembling the intake manifolds

5 Nm (0.5 m • kg, 3.6 ft • Ib)
T.
R.
4
5 Nm (0.5 m • kg, 3.6 ft • Ib)

T.
R.
New
New
5
New
5
New
1 2

1 Cylinder-#1 injector coupler 1 Disconnect.
2 Cylinder-#2 injector coupler 1 Disconnect.
3 Sub-wire harness 2 1
4 Fuel pipe assembly 1
5 Injector 2
cedure.
6-13
THROTTLE BODIES
ET1D71026
b. Blow out all of the passages with compressed
REMOVING THE FUEL HOSE
air.
1. Disconnect:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel hose (intake manifold assembly to pres-
sure regulator) ET1D71007
EC1D71014 CHECKING THE ROLLOVER VALVES

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

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

OPERATION
EAS26980
1. Check:
CHECKING THE INJECTORS
• Pressure regulator operation
1. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Injectors a. Remove the pressure regulator cover.
Damage → Replace. Refer to “THROTTLE BODIES” on page 6-6.
EAS26990 b. Disconnect the fuel hose “1” from the pres-
CHECKING THE THROTTLE BODIES sure regulator “2”.
1. Check: c. Connect the fuel pressure adapter “3” be-
• Throttle bodies tween the fuel hose “1” and pressure regula-
Cracks/damage → Replace the throttle bod- tor “2”.
ies as a set. d. Connect the pressure gauge “4” to the fuel
2. Check: pressure adapter “3”.
• Fuel passages e. Connect the vacuum/pressure pump gauge
Obstructions → Clean. set “5” to the pressure regulator.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle bodies in a petroleum-
based solvent.
Do not use any caustic carburetor cleaning
solution.
6-14
THROTTLE BODIES
EAS27030
Vacuum/pressure pump gauge ADJUSTING THE THROTTLE POSITION

set SENSOR
90890-06756 1. Check:
Mityvac brake bleeding tool • Throttle position sensor
YS-42423 Refer to “CHECKING THE THROTTLE PO-
Pressure gauge SITION SENSOR” on page 7-90.
90890-03153 2. Adjust:
YU-03153 • Throttle position sensor angle
Fuel pressure adapter ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
90890-03176 a. Connect the throttle position sensor coupler
YM-03176 to the throttle position sensor.
b. Connect the digital circuit tester to the throttle
position sensor.
• Positive tester probe
yellow terminal “1”
• Negative tester probe
black terminal “2”
1 Digital circuit tester

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

adjust the fuel pressure in relation to the vac-
uum pressure as described below.
3
TIP
3
The vacuum pressure should not exceed 100
kPa (760 mmHg). 2
1
• Increase the vacuum pressure →
Fuel pressure is decreased
• Decrease the vacuum pressure → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Fuel pressure is increased
ET1D71027
Faulty → Replace the pressure regulator. INSTALLING THE FUEL HOSE

1. Connect:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Fuel hose (intake manifold assembly to pres-
sure regulator)
6-15
THROTTLE BODIES
EC1D71015
NOTICE
When installing the fuel hose, make sure that
it is securely connected, and that the fuel
hose connector cover on the fuel hose is in
the correct position, otherwise the fuel hose
will not be properly installed.
TIP
• Install the fuel hose securely onto the fuel pipe
or pressure regulator until a distinct “click” is
heard.
• To install the fuel hose onto the fuel pipe or
pressure regulator, slide the fuel hose connec-
tor cover “1” on the end of the hose in the direc-
tion of the arrow shown.
6-16
ISC (IDLE SPEED CONTROL) UNIT
ET1D71009

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

T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

Front cylinder head Refer to “CYLINDER HEADS” on page 5-36.
3 2
hose
4 2
hose
5 ISC (idle speed control) unit inlet hose 1
6 Cylinder-#2 left ignition coil 1 For XV19S(C)/ XV19CTS(C)
7 Cylinder-#2 right ignition coil 1 For XV19S(C)/ XV19CTS(C)
8 ISC (idle speed control) unit 1
9 ISC (idle speed control) unit bracket 1
dure.
6-17
ET1D71010
CHECKING THE ISC (IDLE SPEED

CONTROL) SYSTEM
1. Check:
• Hoses
Loose connections → Connect properly.
6-18
6-19
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 7-1

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

CIRCUIT DIAGRAM .................................................................................. 7-7
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 7-9
TROUBLESHOOTING ............................................................................7-10
CHARGING SYSTEM....................................................................................7-13
CIRCUIT DIAGRAM ................................................................................ 7-13
LIGHTING SYSTEM ......................................................................................7-17

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

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

CIRCUIT DIAGRAM ................................................................................ 7-27
ECU SELF-DIAGNOSTIC FUNCTION....................................................7-29
SELF-DIAGNOSTIC FUNCTION TABLE ................................................ 7-30
TROUBLESHOOTING METHOD............................................................ 7-32
DIAGNOSTIC MODE .............................................................................. 7-33
TROUBLESHOOTING DETAILS ............................................................ 7-40
FUEL PUMP SYSTEM...................................................................................7-65

CIRCUIT DIAGRAM ................................................................................ 7-65
TROUBLESHOOTING ............................................................................7-67 7
ELECTRICAL COMPONENTS...................................................................... 7-69
CHECKING THE SWITCHES .................................................................7-73
CHECKING THE BULBS AND BULB SOCKETS ................................... 7-76
CHECKING THE FUSES ........................................................................7-77
CHECKING AND CHARGING THE BATTERY....................................... 7-78
CHECKING THE RELAYS ...................................................................... 7-81
CHECKING THE TURN SIGNAL RELAY ............................................... 7-82
CHECKING THE DIODES....................................................................... 7-83
CHECKING THE IGNITION SPARK GAP............................................... 7-84
CHECKING THE SPARK PLUG CAPS...................................................7-84
CHECKING THE IGNITION COILS......................................................... 7-85
CHECKING THE CRANKSHAFT POSITION SENSOR.......................... 7-85
CHECKING THE LEAN ANGLE SENSOR.............................................. 7-86
CHECKING THE STARTER MOTOR OPERATION ...............................7-86
CHECKING THE STATOR COIL ............................................................ 7-86
CHECKING THE RECTIFIER/REGULATOR ..........................................7-87
CHECKING THE HORNS ....................................................................... 7-87
CHECKING THE ENGINE TEMPERATURE SENSOR .......................... 7-88
CHECKING THE FUEL SENDER (FUEL TANK) .................................... 7-89
CHECKING THE FUEL SENDER (FUEL PUMP) ................................... 7-89
CHECKING THE FUEL LEVEL WARNING LIGHT .................................7-90
CHECKING THE SPEED SENSOR ........................................................ 7-90
CHECKING THE THROTTLE POSITION SENSOR ...............................7-90
CHECKING THE FUEL PUMP................................................................7-91
CHECKING THE EXUP SERVO MOTOR............................................... 7-91
CHECKING THE INTAKE AIR PRESSURE SENSOR ........................... 7-92
CHECKING THE AIR TEMPERATURE SENSOR ..................................7-92
EAS27110
EAS27090
L2 B/R3
L1 R1 Sb/W
R1 L1 B/R3 L/W R/L2
10 L2 L/R R/W L/G L/Y1 Sb B/Y2 Sb/W Br/W P W/R L1 L/B R/B R/L4 R/W4 R/B3 B/W2 B/L4 W/G Br/L Gy/W B/R B1 G G/R2 O2
L1 L2 Y/G Br P/W Gy/Y L/W W/Y2 Gy/B Y/L B/W1 Lg Y Br/Y R/G B/G B2 Gy Y/B G/R1 L/R O1
W1 W2 W3 B1 R2 11 12 (BLACK) (BLACK)
(GRAY) (BLACK) L/R
4 R/L2
5
W1 W1 L3 L/W B/R2 B/R3
R1 R1 R2
W2 W2 R2 R2
1 2 4 R4 R/W B/Y2 L/Y1 Sb L/G A
W3 W3 B4 B1 B2 B3 G/W R/L1
L/W
R2 Sb R/L2 W2
R/L1 R/L3 W1 L/R 4 B/R4 4 B/R1 B/R1
R3 R1 14 25
B G/W B2 O2 Ch Dg
B1 Sb Dg Ch
B 15 16
B B4 B1 B2 B3 R/L1 B1 Y Br B B L Y
B/R B/R3 B/R2
B2 4 R/L4 R/L4 29
B1 (GRAY)
B/R3
CIRCUIT DIAGRAM
O2 26 WIRE HARNESS SUB-WIRE-HARNESS1

13 O1 O1
4 B/Y2 B
R/B R/B
29
B/Y1 L/W B/R2
L/B 27 Gy G Br Br G Gy
R/W4 G/R2 G/R2
IGNITION SYSTEM
W1 W2 B B W2 W1
29
R1 Br Br B Br Br
R3 Br B 17 B/R
B B B B 28 WIRE HARNESS SUB-WIRE-HARNESS2
R1 G/R1 G/R1
7 R/W2 L3 (BLACK) B1 B1 C B1 C
3 6 L Y B1 W1 G 29
ON L3 Y Y C Y Y
R2 R2 18
OFF (BLACK) L L C L 30
8 (GRAY)
G G B G G W1 W1 B W1 Y L L Y
R/W2
R Br/W B/L2 Br/W Br/W B1
L/B L/Y 24 B1
Br/L 19 B/L2 W2 Gy
(RED) B B (BLACK)
31 (DARK GRAY)
Br/L1 L/B B/L4
Gy Gy B Gy Gy W2 W2 B W2 WIRE HARNESS SUB-WIRE-HARNESS2
R3 L/Y3 B B/L4 P/W L4 P/W P/W
L/Y3 L/B L/Y1 B4 B3
9 20 B R/L3
Br/L1 L4
(RED) (BLACK)
R/W2 R/W4 L2 Gy/W Gy/W B
Gy/W R/L3
Y/G Y/G B B
Lg Gy/Y Gy/Y L Gy/Y B/L3
L/Y3 21 B/L3 W L
4 4 B5 L2 Y/G B/L3 Lg Lg B/L3 W
32
(BLACK)
4 Gy Gy/B Gy/B Y/L
B5 22 B/G B/G
L/Y2 B/W5 B1 R/W1 B B/L5
B2 B/R B/R
R/W3 L1
Gy/B B/L5 B Gy W/R W/R
B/L4 L5 W/R B/L2
L5 B/G B/R
B1 4 33
L3 W/Y1 W L B B/L6
L3 (BLACK)
B/L6 23 B/L2
B W W/Y1 B/L1 B/L3 B/L1 B/L2 B/L4
L4 L2 L1 L L5 L3 B/L4 B/L2 B/L5 B/L6 B1 B/L3 B
B B4 B3 R/G R/G
Br/Y Br/Y W/G R/B1 R/G
14 14 14 W/Y2 W/G W/G 34 Br/L R/B2 Br/Y
L4 L L5 B/L1 B/L2 B/L3 B1 B/L1 B/L3 Br/L Br/L (BLACK)
Y/B
W/Y1 L2 L1 L3 B/L4 B/L5 B/L6 B B/L2 B/L4 R/B3
4 W/Y2
R/B1R/B2
W/Y3
70 B1B2B/W2 B/W1 R/B3 R/B2 R/B1 R
R R/B
7-1
14
71 R/B3
R4 R/Y R/B2
R/B1
R
Br/L1 72 B/W1
B/W2
Br/L3 Br/L3 R/W1
4 Br/L2 B/W5 B/W3
Br2 B/W5 B/W1 B/W2 B/W3
14 Sb/W
B/W
4 Br4 Br4
4 Br 35 Sb
Br P1
Br B/W
R/Y (BLACK) 46
Br3 Br1 Br L2 Br2 G/L2 Br2 47 P1 B 36
73 Br Y/B 49
Br/L Br1 Br Y/B P1 Y/L
R/Y G/L2 G/L2 R/B R/G
W/Y3
74 48 Br/W Br2
B G/W
Br/L2 R/W G/L3 W/Y3 Y/R B3 4
4 G/Y
Br/W B3 Y/R R/W3
37 G
75 G/L1 P2
Br/L Br 50 L/Y2 B/Y1 G/L1 Br/W Y/R P2 G/Y
Br3
B3 B4
G Y Y G G
G/L1 G/L
52 53 54 55 38
69 (GREEN) (GREEN)
(L) PUSH G B
R/W
Y1 Br3 60 Y3 Br2 B/R2 L/W G/L3 N 39 45
Br Y B/Y1 L/Y2 B3 B4
(R)
(BLACK) (BLACK) B/W3 G/Y G/Y B/W
B2 B1
Y3 Br2 B1 B2 (BLACK) B3 B2
L/G Br Y1 62 63 64 (BLACK) 40 B2 G
51 B4
B R/L R/W B/R B1 P2 P B1
B/R2 R/W (BLACK)
77 Y1 L/B G/L3 G/LL/B Y/R Y/R 41
4 Y3 (YELLOW) (YELLOW)
B1 L/G B B 76 Y Y R/G Dg Dg3 R/B Y3
B R/L B3 L/W L/W W/B Dg1 Ch1 Ch Dg
(BLACK) (BLACK) R/W Sb Ch Ch3 Sb/W R/W3
Y Br B4 Br/W Br/W 42
B1 Br B2 B2 61 W/B (GRAY)
A A (BLACK) (BLACK) (GRAY)
Y1 G Ch1 Dg1 B1 B/W3 G/Y G/W Y/L
B1 Y/L G/W G/Y
Y L B3 L/B 43 B/W4 G
4 B/W4 G B
B3 B2 Ch3
B1 B2 (BLACK)
Y L Y3 (BLACK)
L 44
Ch A Ch
B3 4 68 Dg A Dg Dg3
L/B
B
67 Ch Dg
Y1 Y3 Y2 Y2 G Ch Ch1Ch3Ch2 Ch2L1 L1 L2 L3 Dg2 L3 Dg2 Dg Dg1Dg3
B 59 B/W4
L Ch Dg
B B B G
66 65 L/B B B5 L/B Ch L 14 Dg L
Y2 B2
(YELLOW) (GRAY) (BLACK) 4 58 4 57 B 56 B 4
B5 (GRAY) L3 L2 L1 (BLACK)
B B B B5 B
Y L L Y
L Ch Dg B2 B3 B4
B B L1 Ch2 L3 Dg2
B B B B3 B4
B2
B (YELLOW) (GRAY) (BLACK) B B2 B3 B3 (GRAY) (BLACK)
B5 14 B4
B4
B A B
IGNITION SYSTEM
IGNITION SYSTEM
3. Main switch
4. Joint
5. Main fuse
6. Battery
10.Relay unit
13.Neutral switch
14.Joint connector (for XV19CS(C)/ XV19C(C))
21.Lean angle sensor
22.Crankshaft position sensor
24.ECU (engine control unit)
25.Cylinder-#1 left ignition coil
26.Cylinder-#1 right ignition coil
29.Spark plug
62.Engine stop switch
72.ECU fuse
74.Ignition fuse
77.Sidestand switch
7-2
IGNITION SYSTEM
ET1D71043
ENGINE STOPPING DUE TO SIDESTAND OPERATION

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

(Main, ignition, and ECU)
Replace the fuse(s).
Refer to “CHECKING THE FUS-
ES” on page 7-77.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 7-78.
OK ↓
3. Check the spark plugs. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug(s).
PLUGS” on page 3-9.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 7-84.
NG ↓
5. Check the spark plug caps. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap(s).
PLUG CAPS” on page 7-84.
OK ↓
6. Check the ignition coils. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil(s).
TION COILS” on page 7-85.
OK ↓
7. Check the crankshaft position sen- NG →
sor.
Refer to “CHECKING THE CRANK- Replace the crankshaft position sensor.
SHAFT POSITION SENSOR” on
page 7-85.
OK ↓
7-4
IGNITION SYSTEM
8. Check the main switch. NG →

Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-73.
OK ↓
9. Check the engine stop switch. NG →
The engine stop switch is faulty. Replace
Refer to “CHECKING THE
the right handlebar switch.
OK ↓
10.Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
11.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
12.Check the relay unit (diode). NG →
Refer to “CHECKING THE DI- Replace the relay unit.
ODES” on page 7-83.
OK ↓
13.Check the lean angle sensor. NG →
Refer to “CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR” on page 7-86.
OK ↓
14.Check the entire ignition system NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem wiring.
page 7-1.
OK ↓
Replace the ECU.
7-5
IGNITION SYSTEM
7-6
EAS27170
EAS27160
R4 R/Y
5
R R/B
B/R2
6 L2 L1 R/B4 Sb/W
B2 R2 R/B1 R/B4
R/B4 L1 B/R2 L/W R/L2
(BLACK) R/B2 R/B3 Gy/W B/R B1 G Gy/R2 O2 B/R2 B/R1
19 L2 L/R R/Y L/G L/Y Sb B/Y2 Sb/W
B/G B2 Gy Y/B Gy/R1 L/R O1
R4 R1 L1 L2
R 20 21 31 (BLACK)
W1 W1 R/B3 R/B2 B/R3 B/R3
W2 W2 7 R/B2 R/B4 R/B3 R/B1 R/B2 Br/W W/R L1 L/B B/Y3 R/L3 R/W3 R/B2 B/Br2 B/L5 W/G Br/L 4 33
1 R2 R2 R/B3 R/Y L3
W3 W3 2 4 Y/G Br P/W Gy/G L/W W/Y2 Gy2 Y/L B/Br1 Lg Y P/L R/G O2 B
R3 4 R1 R1 R
(BLACK) B/R B/R4 37
W3 W2 W1 R/Y L/Y L/W R/L2 Sb L/G
L3 L/W B/Y2 O2
(GRAY) B2 R/L3 B/R4 Gy G Br Br G Gy
L/R Sb Sb L/G R/B2 34 W2 W B B W W2
14 O1 O1
R3 8 B B
B B/R
L3
CIRCUIT DIAGRAM
R R B 23 4
R C 37
R R3 15 WIRE HARNESS SUB-WIRE-HARNESS2
3 B/R
Br/L Br/L1 R/Y B B B3 L/G
L2 L L3 B/R C
R/Y B (BLACK)
ON (BLACK) 35
B/Y2 22 Gy/R2 Gy/R2 C Gy/R2 Gy/R2
OFF B B3
L/Y L/Y B B/Y3
L/B L/B
17 4 B/Y1 37
Br/L Gy/R1 B/R Gy/R2
B 16 L/R Gy/R2 B/R Gy/R1
L/W B/R
Br/L1 L/B L/Y B/Y3
R/W2 R/W1 R/W1 L/B Gy/R1 Gy/R1 C Gy/R1 Gy/R1
36
R/W2 R/W3
R/Y
WIRE HARNESS SUB-WIRE-HARNESS3
Y/B R/G R/G D R/G R/G 37
P/L P/L D P/L P/L R/L2 R/L3 D
Br/L1 B2 B2 E B2 W/G W/G D W/G W/G 38
L Y B2 Y Y E Y Y W/G R/B1 R/G
Br Y/B 32 Br/L Br/L D Br/L Br/L
R/Y G/L2
24 Br/L R/B2 P/L
9 (BLACK) L L E L W/G R/B1 R/G R/G R/B1 W/G
4 Br/L2 Br/L2 R/W R/W1 Br B R/B1 R/B2
4 Br/L R/B2 P/L P/L R/B2 Br/L
R/W2 R/W3 18 B B B B R/B2 D R/B2
(BLACK)
25 Br Br B Br Br R/B1 D R/B1 (BLACK) (BLACK)
10 W W2 R/L1
R/Y
Br/L3 R/W4 B/L2 W G
Br/L R/W R/W G/L2 Br/W B/L2 WIRE HARNESS SUB-WIRE-HARNESS4
4 R/W5 Br Y/B 26 Br/W Br/W 39
(BLACK) (GRAY) E
G G B G G W W B W
L3
B/L3 P/W L3 P/W P/W
11 27 B/L3 W2 Gy
Br/L3 Br1 (BLACK)
Lg Lg 40 (DARK GRAY) Y L L Y
L3 Gy Gy B Gy Gy W2 W2 B W2 B2 B2
Lg B/L2
12 L3 Y/G B/L2
28 Y/G Y/G
Br/L4 Br Y/L
Gy/W
B B/L2 WIRE HARNESS SUB-WIRE-HARNESS2
L4 W/Y1
ELECTRIC STARTING SYSTEM
W L B/G B/G
L L4 L1
B/L2 B 29 W W/Y1 W/Y2 B/R B/R L5 W/R B/L4
Br B/L5 L5 B/G B/R
Gy Gy2 Gy2 W/R W/R 41
R/L B/L4 (BLACK)
30 B B/L1 Gy/G
13 Gy2 B/L1 B Gy L4 L3 L2 L1 B/L1 B/L2 B/L5 B/L6 B/L2 B/L3 B/L6 B/L1 B/L1 B/L2 B B2
B R/L
B1 B2 B/Br2
W/Y1 B/Br1 B/Br2
Br B4 B4 4
W/Y2 4 4 4 4 B/Br1
4 W/Y3
42 B B Gy/W R/W4
L5 B/L3 B/L4 B/Br3 Gy/G L W L Gy/G B/L3
7-7
(BLACK)
B/L3 W
R/W4 B B Gy/W
B5 B4 B3 B1 B2 B/Br3
B4
4 B6 B6 4 B5
B1 B2
Br6 Br1
Br6 B/W
B5 B1 B2 B3 B4
Br2
B 4 Br4 Br2 P1
76 Br3 Br2 43
(BLACK) B/W
31 44
W/Y3 Br4
57 P1 56 4 Sb Sb/W
Y1 Br6 B B1 B2 B3 B4
B B
B P1
(BLACK) (BLACK) 4 R/B R/G Y L Dg Dg4 L3 Y3
Br/W Br4 B4 W/B B3 B2 B1
Y1 W/Y3 Y/R B1
58 B Y/L R/W Sb Ch Ch4 Sb/W R/W5
P2 R/W5 R/W
Br/W B1 Y/R G
Y1
R/W G/L2 G/W Y/L G/W R/G R/B G/W Y/L
70 Br5 Y3 B/R1 L/W G/L3 G/L3 G/L1 59 L/Y B/Y1 G/L1 Br/W Y/R P2 G B B3 G
G/Y 45
Y3 B2 B3 G/L P (BLACK)
4 B1 B2 B/R G/L G Y1 (BLACK)
B/R1 R/W Y G G/Y
46
R/W B/R G/L1 61 62 63 64
L/B G/L3 G/L G/Y
G/LL/B 4 G/B G/Y
Y2 (BLUE) (BLUE)
72 73 74 (L) PUSH G/B G/B
G
N G/W R/L1
Y3 Br5 B1 B2 B/Y1 L/Y B2 B3 G/B (BLACK) (BLACK)
(R)
G/B G/Y G/Y G/B 55
W/B L/W L/W W/B (GRAY) 4 4 47
(GRAY) 54 53
B2
71 60 B2 G G B
B4 P2 P B B3
(BLACK) (BLACK) Ch1 Ch3 Ch2 Ch4 Dg1 Dg3 Dg2 Dg4 48
Y/R Y/R
B3 B2
W/B L/B (GRAY) (GRAY) G/W B3
B2 R/L1 B2
Dg1 Ch1 Ch Dg
Br/W Br/W 49
(GRAY) Y Ch Dg B
(GRAY) Dg4 Dg
Y1 G Ch1 Dg1 B4
50
Ch4 Ch
77 Y2 L1 Ch3 Dg3
Y L Ch Dg 51
L3 L
52
Y3 Y
Y1 Ch2 L5 Dg2 L4
Y3 B
78 79 80 81 4 Ch L Dg L
L1 Br3 Br5 L3 L4 L5 L/B Y2 Y2 G 67 Ch L
L5 Ch2 Dg L L4 Dg2 B3
B3 B 66 65 B B6
75 B4 Y2 Y B 68 69 B5 G (GRAY) (GRAY) B B (BLACK) (BLACK)
4 (BLACK) (BLACK)
L/B B B2 L/B B3 B6 B6
Ch3 Dg3 Dg Ch B B4 B5 B5
Y2 L1 B5 B L Y B B4 B1 B2 B3
B2 B3 31 B4 B5 B6
B5 B2
B1
3. Main switch
4. Joint
7. Main fuse
8. Battery
9. Ignition fuse
10.ECU fuse
15.Starter relay
16.Starter motor
17.Diode (for XV19S(C)/ XV19CTS(C))
19.Relay unit
20.Starting circuit cut-off relay
22.Neutral switch
23.Sidestand switch
60.Clutch switch
73.Start switch
7-8
EAS27180
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” and the main switch is turned “ON” (both switch circuits are
closed), the starter motor can only operate if at least one of the following conditions is met:
• The transmission is in neutral (the neutral switch circuit is closed).
• The clutch lever is pulled to the handlebar (the clutch switch circuit is closed) and the sidestand is up
(the sidestand switch circuit is closed).
The starting circuit cut-off relay prevents the starter motor from operating when neither of these condi-
tions has been met. In this instance, the starting circuit cut-off relay stays open so current cannot reach
the starter motor. When at least one of the above conditions has been met, the starting circuit cut-off
relay is closed and the engine can be started by pushing the start switch “ ”.
15
13
1
2
3 12
4 11
7
7
8 a
7
9 10 14
b
16
a. WHEN THE TRANSMISSION IS IN 8. Clutch switch

NEUTRAL 9. Sidestand switch
b. WHEN THE SIDESTAND IS UP AND THE 10. Neutral switch
CLUTCH LEVER IS PULLED TO THE
HANDLEBAR 11. ECU fuse
1. Battery 12. Diode (for XV19S(C)/ XV19CTS(C))
2. Main fuse 13. Starter relay
3. Main switch 14. Start switch
4. Ignition fuse 15. Starter motor
5. Engine stop switch 16. ECU (engine control unit)
6. Relay unit (starting circuit cut-off relay)
7. Relay unit (diode)
7-9
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Rider seat
2. Tool kit tray

(Main, ignition, and ECU)
ES” on page 7-77.
OK ↓
page 7-78.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
7-86.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-85.
OK ↓
5. Check the relay unit (starting circuit NG →
cut-off relay).
Replace the relay unit.
Refer to “CHECKING THE RE-
LAYS” on page 7-81.
OK ↓
6. Check the relay unit (diode). NG →
OK ↓
7. Check the diode. (for XV19S(C)/ NG →
XV19CTS(C))
Replace the diode.
Refer to “CHECKING THE DI-
OK ↓
7-10
8. Check the starter relay. NG →

Refer to “CHECKING THE RE- Replace the starter relay.
OK ↓
OK ↓
10.Check the engine stop switch. NG →
OK ↓
11.Check the neutral switch. NG →
OK ↓
12.Check the sidestand switch. NG →
Refer to “CHECKING THE Replace the sidestand switch.
OK ↓
13.Check the clutch switch. NG →
Refer to “CHECKING THE Replace the clutch switch.
OK ↓
14.Check the start switch. NG →
The start switch is faulty. Replace the right
handlebar switch.
OK ↓
15.Check the entire starting system NG →
wiring. Properly connect or repair the starting sys-
page 7-7.
OK ↓
The starting system circuit is OK.
7-11
7-12
CHARGING SYSTEM
EAS27200
CHARGING SYSTEM
EAS27210
CIRCUIT DIAGRAM
L2 B/R3
L1 R1 Sb/W
R1 L1
10 L2 L/R R/W L/G L/Y
L1 L2
W1 W2 W3 B1 R2 11 12
(GRAY) (BLACK)
4 L/R
R/L2
5
W1 W1 L3 L/W
R1 R1 R2
1 W2
W3
W2
W3 2 R2 R2 4 R4 R/W B/Y2 L/Y1 Sb L/G
B4 B1 B2 B3 G/W
L/W
R2 Sb
R3 R1
B 14
B1 Sb B
B B4 B1 B2 B3
15
B2
B1
13
4 B/Y2
R/B
B/Y1
R1
R3 Br B 17 Br
B
Br B Br
B B B
R1
3 6 7 R/W2 L3 (BLACK) B1 B1 C B1
ON R2 R2 L3
L Y B1
18 Y Y C Y
OFF
8 (BLACK) L L C L
R/W2
R
L/B L/Y
Br/L
Br/W B/L2
19 Br/W
B/L2
(RED) B B (BLACK)
Br/L1 L/B B/L4
L/Y3 L/B
R3
Br/L1
L/Y3
L/Y1 B4 B3
B 9 B/L4 P/W L4 20 P/W
L4
(RED) (BLACK)
R/W2 R/W4 L2
Y/G
L/Y3
4 4 B5
Lg
L2 Y/G B/L3
21 B/L3
Lg
4 Gy Gy/B
L/Y2 B/W5 B1
B5
R/W1
22 B B/L5
B2 R/W3
Gy/B B/L5 B Gy
B1 4 L3 W/Y1 W L B B/L6
B/L6 B 23 W
L3
W/Y1 B/L1 B
L4 L2 L1 L L5 L3 B/L4
B B4 B3
14 14
L4 L L5 B/L1
W/Y1 L2 L1 L3 B/L4
4 W/Y2
W/Y3
70
R R/B
71
R4 R/Y
Br/L1 72
4 Br/L3
Br/L2
Br/L3 R/W1
Br2
B/W
4 Br4 Br4
4 Br
R/Y
Br3 Br1 Br L2 Br2
73 Br
G/L2
Y/B
Br/L Br1
74
Br/L2 R/W
75
Br/L Br
Br3
G Y
G/L1
69 (GREEN)
R/W
Y1 Br3 Br Y 60 Y3 Br2 B/R2 L/W G/L3 B/Y1 L/Y2
(BLACK) (BLACK) B/W3 G/Y
B2 B1
L/G Br Y1
Y3 Br2 B1 B2
62 63 64 (BLACK)
B R/L B/R2 R/W R/W B/R B1 P2

77 Y1 L/B G/L3 G/LL/B Y/R
B1 L/G B B 76 4 Y3
Y
(YELLOW)
B R/L B3 L/W L/W W/B Dg1 Ch1
(BLACK) (BLACK)
B1 Br B2 B2
Y Br
(BLACK) (BLACK)
61 W/B
B4 Br/W
(GRAY)
A A
B3 L/B B1
B1 B2
Y L
B3 4 B/W4
B2
Y L
L
Ch A Ch
B3 4 68 Dg A Dg
L/B
67 Ch Dg
B L Ch Dg
59
B 66 B 65 B L/B B B5 L/B
(YELLOW) (GRAY) (BLACK)
B5
B B B B5 B
7-13
CHARGING SYSTEM
1. AC magneto
2. Rectifier/regulator
4. Joint
5. Main fuse
6. Battery
7-14
CHARGING SYSTEM
EAS27220
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Rider seat
2. Rectifier/regulator cover
3. Lead cover
1. Check the fuse. NG →

(Main)
Replace the fuse.
ES” on page 7-77.
OK ↓
page 7-78.
OK ↓
3. Check the stator coil. NG →
Refer to “CHECKING THE STATOR Replace the stator coil.
COIL” on page 7-86.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 7-87.
OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 7-13.
OK ↓
The charging system circuit is OK.
7-15
CHARGING SYSTEM
7-16
EAS27250
EAS27240
L2 B/R3
L1 R1 Sb/W
R1 L1 B/R3 L/W R/L2
(GRAY) (BLACK) L/R
4 R/L2
5
R1 R1 R2
W2 W2 R2 R2
1 2 4 R4 R/W B/Y2 L/Y1 Sb L/G A
W3 W3 B4 B1 B2 B3 G/W R/L1
L/W
R2 Sb R/L2 W2
R/L1 R/L3 W1 L/R 4 B/R4 4 B/R1 B/R1
R3 R1 14 25
B G/W B2 O2 Ch Dg
B1 Sb Dg Ch
B 15 16
B/R B/R3 B/R2
B2 4 R/L4 R/L4 29
B1 (GRAY)
B/R3
CIRCUIT DIAGRAM

13 O1 O1
4 B/Y2 B
R/B R/B
29
B/Y1 L/W B/R2
R/W4 G/R2 G/R2
W1 W2 B B W2 W1
LIGHTING SYSTEM
29
R1 Br Br B Br Br
R3 Br B 17 B/R
R1 G/R1 G/R1
3 6 L Y B1 W1 G 29
ON L3 Y Y C Y Y
R2 R2 18
8 (GRAY)
R/W2
L/B L/Y 24 B1
Br/L 19 B/L2 W2 Gy
(RED) B B (BLACK)
31 (DARK GRAY)
Br/L1 L/B B/L4
L/Y3 L/B L/Y1 B4 B3
9 20 B R/L3
Br/L1 L4
(RED) (BLACK)
Gy/W R/L3
Y/G Y/G B B
L/Y3 21 B/L3 W L
32
(BLACK)
4 Gy Gy/B Gy/B Y/L
B5 22 B/G B/G
B2 B/R B/R
R/W3 L1
B/L4 L5 W/R B/L2
L5 B/G B/R
B1 4 33
L3 W/Y1 W L B B/L6
L3 (BLACK)
B/L6 23 B/L2
B B4 B3 R/G R/G
14 14 14 W/Y2 W/G W/G 34 Br/L R/B2 Br/Y
Y/B
4 W/Y2
R/B1R/B2
W/Y3
70 B1B2B/W2 B/W1 R/B3 R/B2 R/B1 R
R R/B
7-17
14
71 R/B3
R4 R/Y R/B2
R/B1
R
Br/L1 72 B/W1
B/W2
Br/L3 Br/L3 R/W1
4 Br/L2 B/W5 B/W3
14 Sb/W
B/W
4 Br4 Br4
4 Br 35 Sb
Br P1
Br B/W
R/Y (BLACK) 46
73 Br Y/B 49
W/Y3
74 48 Br/W Br2
B G/W
4 G/Y
Br/W B3 Y/R R/W3
37 G
75 G/L1 P2
Br3
B3 B4
G Y Y G G
G/L1 G/L
52 53 54 55 38
69 (GREEN) (GREEN)
(L) PUSH G B
R/W
Y1 Br3 60 Y3 Br2 B/R2 L/W G/L3 N 39 45
(R)
B2 B1
L/G Br Y1 62 63 64 (BLACK) 40 B2 G
51 B4
B/R2 R/W (BLACK)
B1 Y/L G/W G/Y
4 B/W4 G B
B3 B2 Ch3
B1 B2 (BLACK)
Y L Y3 (BLACK)
L 44
Ch A Ch
B3 4 68 Dg A Dg Dg3
L/B
B
67 Ch Dg
B 59 B/W4
L Ch Dg
B B B G
66 65 L/B B B5 L/B Ch L 14 Dg L
Y2 B2
B B B B5 B
Y L L Y
L Ch Dg B2 B3 B4
B B L1 Ch2 L3 Dg2
B B B B3 B4
B2
B5 14 B4
B4
B A B
LIGHTING SYSTEM
LIGHTING SYSTEM
3. Main switch
4. Joint
5. Main fuse
6. Battery
14.Joint connector
41.Meter light
42.High beam indicator light
49.Headlight relay
52.Dimmer switch
56.Front right turn signal/position light
57.Front left turn signal/position light
58.Headlight
59.Accessory light (OPTION)
64.Accessory light switch
67.License plate light
68.Tail/brake light
71.Headlight fuse
72.ECU fuse (for XV19CS(C)/ XV19C(C))
73.Signaling system fuse
7-18
LIGHTING SYSTEM
EAS27260
TROUBLESHOOTING
Any of the following fail to light: headlight (high beam), headlight (low beam), high beam indicator light,
taillight, license light, position light, meter light or accessory light (OPTION).
TIP
1. Rider seat
2. Tool kit tray
1. Check the condition of each bulb NG →

and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
7-76.
OK ↓
(Main, headlight, signaling system,
and ECU (for XV19CS(C)/
XV19C(C))
ES” on page 7-77.
OK ↓
page 7-78.
OK ↓
OK ↓
5. Check the dimmer switch. NG →
The dimmer switch is faulty. Replace the
left handlebar switch.
OK ↓
6. Check the accessory light switch. NG →
The accessory light switch is faulty. Re-
place the right handlebar switch.
OK ↓
7. Check the headlight relay. NG →
Refer to “CHECKING THE RE- Replace the headlight relay.
OK ↓
7-19
LIGHTING SYSTEM
8. Check the entire lighting system NG →

wiring. Properly connect or repair the lighting sys-
page 7-17.
OK ↓
The lighting system circuit is OK.
7-20
EAS27280
EAS27270
L2 B/R3
L1 R1 Sb/W
R1 L1 B/R3 L/W R/L2
(GRAY) (BLACK) L/R
4 R/L2
5
R1 R1 R2
W2 W2 R2 R2
1 2 4 R4 R/W B/Y2 L/Y1 Sb L/G A
W3 W3 B4 B1 B2 B3 G/W R/L1
L/W
R2 Sb R/L2 W2
R/L1 R/L3 W1 L/R 4 B/R4 4 B/R1 B/R1
R3 R1 14 25
B G/W B2 O2 Ch Dg
B1 Sb Dg Ch
B 15 16
B/R B/R3 B/R2
B2 4 R/L4 R/L4 29
B1 (GRAY)
B/R3
CIRCUIT DIAGRAM

13 O1 O1
4 B/Y2 B
R/B R/B
29
B/Y1 L/W B/R2
R/W4 G/R2 G/R2
W1 W2 B B W2 W1
29
R1 Br Br B Br Br
R3 Br B 17 B/R
SIGNALING SYSTEM
R1 G/R1 G/R1
3 6 L Y B1 W1 G 29
ON L3 Y Y C Y Y
R2 R2 18
8 (GRAY)
R/W2
L/B L/Y 24 B1
Br/L 19 B/L2 W2 Gy
(RED) B B (BLACK)
31 (DARK GRAY)
Br/L1 L/B B/L4
L/Y3 L/B L/Y1 B4 B3
9 20 B R/L3
Br/L1 L4
(RED) (BLACK)
Gy/W R/L3
Y/G Y/G B B
L/Y3 21 B/L3 W L
32
(BLACK)
4 Gy Gy/B Gy/B Y/L
B5 22 B/G B/G
B2 B/R B/R
R/W3 L1
B/L4 L5 W/R B/L2
L5 B/G B/R
B1 4 33
L3 W/Y1 W L B B/L6
L3 (BLACK)
B/L6 23 B/L2
B B4 B3 R/G R/G
14 14 14 W/Y2 W/G W/G 34 Br/L R/B2 Br/Y
Y/B
4 W/Y2
R/B1R/B2
W/Y3
70 B1B2B/W2 B/W1 R/B3 R/B2 R/B1 R
R R/B
7-21
14
71 R/B3
R4 R/Y R/B2
R/B1
R
Br/L1 72 B/W1
B/W2
Br/L3 Br/L3 R/W1
4 Br/L2 B/W5 B/W3
14 Sb/W
B/W
4 Br4 Br4
4 Br 35 Sb
Br P1
Br B/W
R/Y (BLACK) 46
73 Br Y/B 49
W/Y3
74 48 Br/W Br2
B G/W
4 G/Y
Br/W B3 Y/R R/W3
37 G
75 G/L1 P2
Br3
B3 B4
G Y Y G G
G/L1 G/L
52 53 54 55 38
69 (GREEN) (GREEN)
(L) PUSH G B
R/W
Y1 Br3 60 Y3 Br2 B/R2 L/W G/L3 N 39 45
(R)
B2 B1
L/G Br Y1 62 63 64 (BLACK) 40 B2 G
51 B4
B/R2 R/W (BLACK)
B1 Y/L G/W G/Y
4 B/W4 G B
B3 B2 Ch3
B1 B2 (BLACK)
Y L Y3 (BLACK)
L 44
Ch A Ch
B3 4 68 Dg A Dg Dg3
L/B
B
67 Ch Dg
B 59 B/W4
L Ch Dg
B B B G
66 65 L/B B B5 L/B Ch L 14 Dg L
Y2 B2
B B B B5 B
Y L L Y
L Ch Dg B2 B3 B4
B B L1 Ch2 L3 Dg2
B B B B3 B4
B2
B5 14 B4
B4
B A B
SIGNALING SYSTEM
SIGNALING SYSTEM
3. Main switch
4. Joint
5. Main fuse
6. Battery
10.Relay unit
13.Neutral switch
14.Joint connector
15.Fuel sender (fuel pump)
23.Speed sensor
36.Neutral indicator light
37.Multi-function meter
39.Fuel level warning light
43.Left turn signal indicator light
44.Right turn signal indicator light
45.Fuel sender (fuel tank)
46.Horn 1
47.Horn 2
48.Turn signal relay
53.Turn signal switch
54.Horn switch
56.Front right turn signal/position light
57.Front left turn signal/position light
61.Front brake light switch
65.Rear right turn signal light
66.Rear left turn signal light
68.Tail/brake light
69.Rear brake light switch
70.Backup fuse (odometer and clock)
72.ECU fuse
7-22
SIGNALING SYSTEM
EAS27290
TROUBLESHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
• The fuel level gauge fails to operate.
• The speedometer fails to operate.
TIP
1. Rider seat
2. Tool kit tray
5. Fuel tank

(Main, backup, signaling system,
and ECU) Replace the fuse(s).
ES” on page 7-77.
OK ↓
page 7-78.
OK ↓
OK ↓
4. Check the entire signaling system NG →
wiring. Properly connect or repair the signaling
page 7-21.
OK ↓
Check the condition of each of the sig-
naling system’s circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

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

Refer to “CHECKING THE Replace the horn(s).
HORNS” on page 7-87.
OK ↓
page 7-21.
OK ↓
This circuit is OK.
The tail/brake light fails to come on.

1. Check the front brake light switch. NG →
Refer to “CHECKING THE Replace the front brake light switch.
OK ↓
2. Check the rear brake light switch. NG →
Refer to “CHECKING THE Replace the rear brake light switch.
OK ↓
page 7-21.
OK ↓
This circuit is OK.
The turn signal light, turn signal indicator light or both fail to blink.
1. Check the condition of each bulb NG →
and bulb socket.
Refer to “CHECKING THE BULBS Replace the bulb(s) and bulb socket(s).
AND BULB SOCKETS” on page
7-76.
OK ↓
2. Check the turn signal switch. NG →
The turn signal switch is faulty. Replace
the left handlebar switch.
OK ↓
3. Check the turn signal relay. NG →
Refer to “CHECKING THE TURN Replace the turn signal relay.
SIGNAL RELAY” on page 7-82.
OK ↓
7-24
SIGNALING SYSTEM

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

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

1. Check the fuel sender (fuel tank). NG →
Refer to “CHECKING THE FUEL
Replace the fuel sender.
SENDER (FUEL TANK)” on page
7-89.
OK ↓
page 7-21.
OK ↓
Replace the meter assembly.
The fuel level warning light fails to come on.

1. Check the fuel level warning light. NG →
Refer to “CHECKING THE FUEL Replace the meter assembly or fuel pump
LEVEL WARNING LIGHT” on page assembly.
7-90.
OK ↓
7-25
SIGNALING SYSTEM
2. Check the fuel sender (fuel pump). NG →

Refer to “CHECKING THE FUEL
Replace the fuel pump assembly.
SENDER (FUEL PUMP)” on page
7-89.
OK ↓
page 7-21.
OK ↓
This circuit is OK.
The speedometer fails to operate.

1. Check the speed sensor. NG →
Refer to “CHECKING THE SPEED Replace the speed sensor.
SENSOR” on page 7-90.
OK ↓
page 7-21.
OK ↓
Replace the meter assembly.
7-26
EAS27340
EAS27330
L2 B/R3
L1 R1 Sb/W
R1 L1 B/R3 L/W R/L2
(GRAY) (BLACK) L/R
4 R/L2
5
R1 R1 R2
W2 W2 R2 R2
1 2 4 R4 R/W B/Y2 L/Y1 Sb L/G A
W3 W3 B4 B1 B2 B3 G/W R/L1
L/W
R2 Sb R/L2 W2
R/L1 R/L3 W1 L/R 4 B/R4 4 B/R1 B/R1
R3 R1 14 25
B G/W B2 O2 Ch Dg
B1 Sb Dg Ch
B 15 16
B/R B/R3 B/R2
B2 4 R/L4 R/L4 29
B1 (GRAY)
B/R3
CIRCUIT DIAGRAM

13 O1 O1
4 B/Y2 B
R/B R/B
29
B/Y1 L/W B/R2
R/W4 G/R2 G/R2
W1 W2 B B W2 W1
29
R1 Br Br B Br Br
R3 Br B 17 B/R
R1 G/R1 G/R1
3 6 L Y B1 W1 G 29
ON L3 Y Y C Y Y
R2 R2 18
8 (GRAY)
R/W2
L/B L/Y 24 B1
Br/L 19 B/L2 W2 Gy
(RED) B B (BLACK)
31 (DARK GRAY)
Br/L1 L/B B/L4
L/Y3 L/B L/Y1 B4 B3
9 20 B R/L3
Br/L1 L4
FUEL INJECTION SYSTEM
(RED) (BLACK)
Gy/W R/L3
Y/G Y/G B B
L/Y3 21 B/L3 W L
32
(BLACK)
4 Gy Gy/B Gy/B Y/L
B5 22 B/G B/G
B2 B/R B/R
R/W3 L1
B/L4 L5 W/R B/L2
L5 B/G B/R
B1 4 33
L3 W/Y1 W L B B/L6
L3 (BLACK)
B/L6 23 B/L2
B B4 B3 R/G R/G
14 14 14 W/Y2 W/G W/G 34 Br/L R/B2 Br/Y
Y/B
4 W/Y2
R/B1 R/B2
W/Y3
70 B1B2B/W2 B/W1 R/B3 R/B2 R/B1 R
R R/B
7-27
14
71 R/B3
R4 R/Y R/B2
R/B1
R
Br/L1 72 B/W1
B/W2
Br/L3 Br/L3 R/W1
4 Br/L2 B/W5 B/W3
14 Sb/W
B/W
4 Br4 Br4
4 Br 35 Sb
Br P1
Br B/W
R/Y (BLACK) 46
73 Br Y/B 49
W/Y3
74 48 Br/W Br2
B G/W
4 G/Y
Br/W B3 Y/R R/W3
37 G
75 G/L1 P2
Br3
B3 B4
G Y Y G G
G/L1 G/L
52 53 54 55 38
69 (GREEN) (GREEN)
(L) PUSH G B
R/W
Y1 Br3 60 Y3 Br2 B/R2 L/W G/L3 N 39 45
(R)
B2 B1
L/G Br Y1 62 63 64 (BLACK) 40 B2 G
51 B4
B/R2 R/W (BLACK)
B1 Y/L G/W G/Y
4 B/W4 G B
B3 B2 Ch3
B1 B2 (BLACK)
Y L Y3 (BLACK)
L 44
Ch A Ch
B3 4 68 Dg A Dg Dg3
L/B
B
67 Ch Dg
B 59 B/W4
L Ch Dg
B B B G
66 65 L/B B B5 L/B Ch L 14 Dg L
Y2 B2
B B B B5 B
Y L L Y
L Ch Dg B2 B3 B4
B B L1 Ch2 L3 Dg2
B B B B3 B4
B2
B5 14 B4
B4
B A B
3. Main switch
4. Joint
5. Main fuse
6. Battery
7. Fuel injection system fuse
10.Relay unit
11.Starting circuit cut-off relay
12.Fuel pump relay
13.Neutral switch
14.Joint connector
16.Fuel pump
17.Engine temperature sensor
18.Throttle position sensor
19.Air temperature sensor
20.Intake air pressure sensor
21.Lean angle sensor
22.Crankshaft position sensor
23.Speed sensor
29.Spark plug
30.Injector #2
31.Injector #1
32.O2 sensor
33.EXUP servo motor
34.ISC (idle speed control) unit
37.Multi-function meter
38.Engine trouble warning light
40.Reset switch
49.Headlight relay
55.Select switch
72.ECU fuse
74.Ignition fuse
77.Sidestand switch
7-28
EAS27350
ECU SELF-DIAGNOSTIC FUNCTION

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

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

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

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

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

Able / un-
Fault Able / un-
drive
No signals are received from the
Er-1 tion Unable Unable
ECU.
(output signal error)
No signals are received from the
ECU within the specified duration.
Data from the ECU cannot be re-
ceived correctly.
Non-registered data has been re-
ceived from the meter.
(input signal error)
EAS27400
4. Turn the main switch to “OFF” and back to
TROUBLESHOOTING METHOD
“ON”, then check that no fault code number is
displayed.
The engine operation is not normal and the
engine trouble warning light comes on. TIP
1. Check: If fault codes are displayed, repeat steps (1) to
• Fault code number (4) until no fault code number is displayed.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5. Erase the malfunction history in the diagnos-
a. Check the fault code number displayed on
tic mode. Refer to “Sensor operation table
the meter.
(Diagnostic code No. 62)”.
b. Identify the faulty system with the fault code.
Refer to “Self-Diagnostic Function table”. TIP
c. Identify the probable cause of the malfunc- Turning the main switch to “OFF” will not erase
tion. Refer to “Diagnostic code table”. the malfunction history.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check and repair the probable cause of mal- The engine operation is not normal but the
function. engine trouble warning light does not come
Fault code No. No fault code No. on.
1. Check the operation of following sensors and
Check and repair. Check and repair. actuators in the Diagnostic mode. Refer to
Refer to “TROUBLE- Refer to “Self-Diag- “Sensor operation table” and “Actuator oper-
SHOOTING DE- nostic Function ta- ation table”.
TAILS” on page 7-40. ble”.
Monitor the opera- 01: Throttle position sensor (throttle angle)
tion of the sensors 30: Cylinder-#1 ignition coil
and actuators in the 31: Cylinder-#2 ignition coil
diagnostic mode. Re- 32: Cylinder-#1 ignition coil
fer to “Sensor opera- 33: Cylinder-#2 ignition coil
tion table” and 36: Injector #1
“Actuator operation 37: Injector #2
table”.
If a malfunction is detected in the sensors or
3. Perform ECU reinstatement action. actuators, repair or replace all faulty parts.
Refer to “Reinstatement method” of table in If no malfunction is detected in the sensors
“TROUBLESHOOTING DETAILS”. and actuators, check and repair inner parts of
the engine.
7-32
EAS27420
DIAGNOSTIC MODE
Setting the diagnostic mode
1. Turn the main switch to “OFF” and set the engine stop switch to “ ”.
2. Disconnect the wire harness coupler from the fuel pump.
3. Press and hold the “RESET” switch, turn the main switch to “ON”, and continue to press the switch
for 8 seconds or more.
“SELECT” “RESET”
TIP
• All displays on the meter disappear except the clock and odometer/trip meter/fuel reserve trip
meter/clock displays.
• “dIAG” appears on the odometer/trip meter/fuel reserve trip meter/clock LCD.
4. Simultaneously press the “SELECT” and “RESET” switches for 2 seconds or more to activate the
diagnostic mode. The diagnostic code number “d01” appears on the clock LCD.
5. Set the engine stop switch to “ ”.
6. Select the diagnostic code number corresponding to the fault code number by pressing the “SE-
LECT” and “RESET” switches.
TIP
• To decrease the selected diagnostic code number, press the “RESET” switch. Press the “RESET”
switch for 1 second or longer to automatically decrease the diagnostic code numbers.
• To increase the selected diagnostic code number, press the “SELECT” switch. Press the “SELECT”
switch for 1 second or longer to automatically increase the diagnostic code numbers.
“d01 d70” “d70 d01”
7. Verify the operation of the sensor or actuator.

• Sensor operation
The data representing the operating conditions of the sensor appears on the odometer/trip meter/fu-
el reserve trip meter/clock LCD.
• Actuator operation
Set the engine stop switch to “ ” to operate the actuator.
TIP
If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again.
7-33
8. Turn the main switch to “OFF” to cancel the diagnostic mode.
Diagnostic code table

Fault
Diagnostic
code Symptom Probable cause of malfunction
code No.
No.
• Open or short circuit in wire harness.
• Defective crankshaft position sensor.
No normal signals are re-
• Malfunction in crankshaft position sensor
12 ceived from the crankshaft —
rotor.
position sensor.
• Malfunction in ECU.
• Improperly installed sensor.
Intake air pressure sensor: • Open or short circuit in wire harness.
13 open or short circuit detect- • Defective intake air pressure sensor. 03
ed. • Malfunction in ECU.
Intake air pressure sensor:
• Intake air pressure sensor hose is de-
hose system malfunction
14 tached, clogged, kinked, or pinched. 03
(clogged or detached
hose).
• Open or short circuit in wire sub lead.
Throttle position sensor: • Open or short circuit in wire harness.
15 open or short circuit detect- • Defective throttle position sensor. 01
ed. • Malfunction in ECU.
• Improperly installed throttle position sensor.
EXUP servo motor circuit: • Open or short circuit in wire harness.
17 open or short circuit detect- • Defective EXUP servo motor (potentiome- 53
ed. ter circuit).
18 EXUP servo motor is stuck. • Stuck EXUP servo motor (mechanism). 53
• Stuck EXUP servo motor (motor).
A break or disconnection of
• Open circuit in wire harness (ECU coupler).
19 the blue/black lead of the 20
ECU is detected.
Air temperature sensor:
• Defective air temperature sensor.
22 open or short circuit detect- 05
ed.
• Improperly installed air temperature sensor.
No normal signal is re- • Defective O2 sensor.
24 ceived from the O2 sensor. —
Engine temperature sen- • Open or short circuit in wire harness.
28 sor: open or short circuit • Defective engine temperature sensor. 11
detected. • Malfunction in ECU.
The vehicle has over- • Overturned.
30 08
turned. • Malfunction in ECU.
7-34
Fault
Diagnostic
code No.
No.
Malfunction detected in the • Malfunction in cylinder-#1 left or right igni-
primary wire of the cylin- tion coil. 30
33
der-#1 left or right ignition • Malfunction in ECU. 32
coil. • Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the
• Malfunction in cylinder-#2 left or right igni-
primary wire of the cylin- 31
34 tion coil.
der-#2 left or right ignition 33
coil.
• Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the • Malfunction in cylinder-#1 left or right igni-
primary wire of the cylin- tion coil. 30
35
der-#1 left or right ignition • Malfunction in ECU. 32
coil. • Malfunction in a component of ignition cut-
off circuit system.
Malfunction detected in the
• Malfunction in cylinder-#2 left or right igni-
primary wire of the cylin- 31
36 tion coil.
der-#2 left or right ignition 33
coil.
• Malfunction in a component of ignition cut-
off circuit system.
• Open circuit in wire harness.
• Malfunction in throttle body.
• Malfunction in throttle cables.
• ISC valve is stuck fully open due to discon-
nected ISC unit hose or coupler. (High en-
Engine speed is high when
37 gine idle speed is detected with the ISC 54
the engine is idling.
valve stuck fully open even though signals
for the valve to close are continuously being
transmitted by the ECU.)
• ECU fuse is blown.
Injector: open or short cir- • Defective injector. 36
39
cuit detected. • Malfunction in ECU. 37
• Improperly installed injector.
Lean angle sensor: open or
41 • Defective lean angle sensor. 08
7-35
Fault
Diagnostic
code No.
No.
• Open circuit in wire harness.
• Defective speed sensor.
No normal signals are re-
• Malfunction in vehicle speed sensor detect-
ceived from the speed sen-
ed. 07
42 sor.
• Defective neutral switch. 21
Open circuit is detected in
• Malfunction in the engine side of the neutral
the neutral switch.
switch.
The ECU is unable to moni-
tor the battery voltage (an • Open or short circuit in wire harness.
43 09
open or short circuit in the • Malfunction in ECU.
line to the ECU).
Error is detected while
• Malfunction in ECU. (The CO adjustment
reading or writing on EE-
44 value is not properly written on or read from 60
PROM (CO adjustment val-
the internal memory).
ue).
Power supply to the fuel in-
Malfunction in the charging system. Refer to
46 jection system is not nor- —
“CHARGING SYSTEM” on page 7-13.
mal.
Faulty ECU memory.
(When this malfunction is • Malfunction in ECU. (The program and data
50 detected in the ECU, the are not properly written on or read from the —
fault code number might internal memory.)
not appear on the meter.)
• This fault code number does not indicate a
malfunction.
Engine has been left idling.
• If the engine was stopped by the ECU after
(The ECU automatically
70 idling for 20 minutes, the fault code number —
stops the engine after 20
is stored in the malfunction history. The fault
minutes if it is left idling.)
code number is displayed only when diag-
nostic code No. 61 is executed.
• Malfunction in meter.
No signals are received
Er-1 • Malfunction in ECU. —
from the ECU.
• Defective wire connection of the ECU cou-
pler.
No signals are received • Improper connection in wire harness.
Er-2 from the ECU within the • Malfunction in meter. —
specified duration. • Malfunction in ECU.
• Improper connection in wire harness.
Data from the ECU cannot
Er-3 • Malfunction in meter. —
be received correctly.
Non-registered data has • Improper connection in wire harness.
Er-4 been received from the • Malfunction in meter. —
meter. • Malfunction in ECU.
7-36
Sensor operation table

Diag-
nostic
Item Meter display Checking method
code
No.
01 Throttle angle
• Fully closed position 12–22 Check with throttle fully
closed.
• Fully opened position 87–107 Check with throttle fully
open.
03 Pressure difference Displays the intake air pres- Set the engine stop switch
(atmospheric pressure and sure. to “ ”, and then push the
intake air pressure) start switch “ ”. (If the dis-
play value changes, the
performance is OK.)
05 Air temperature Displays the air temperature. Compare the actually mea-
sured air temperature with
the meter display value.
07 Vehicle speed pulse 0–999 Check that the number in-
creases when the rear
wheel is rotated. The num-
ber is cumulative and does
not reset each time the
wheel is stopped.
08 Lean angle sensor Remove the lean angle
• Upright 0.4–1.4 sensor and incline it more
than 65 degrees.
• Overturned 3.7–4.4
09 Fuel system voltage Approximately 12.0 Set the engine stop switch
(battery voltage) to “ ”, and then compare
with the actually measured
battery voltage. (If the bat-
tery voltage is lower, per-
form recharging.)
11 Engine temperature Displays the engine tempera- Compare the actually mea-
ture. sured engine temperature
with the meter display val-
ue.
20 Sidestand switch Set on/off the sidestand
• Stand retracted ON switch (with the transmis-
sion in gear).
• Stand extended OFF
21 Neutral switch Shift the transmission.
• Neutral ON
• In gear OFF
53 EXUP servo motor Displays the operating angle. —
Engine trouble warning light
comes on twice: once when
the EXUP valve is closing
and once when it is opening.
7-37
Diag-
nostic
Item Meter display Checking method
code
No.
60 EEPROM fault code dis- —
play
• No history 00
• History exists 01 or 02 (Cylinder fault code)
• (If both cylinders are defec-
tive, the display alternates
every two seconds.)
61 Malfunction history code —
display
• No history 00
• History exists Fault codes 12-70
• (If more than one code
number is detected, the dis-
play alternates every two
seconds to show all the de-
tected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code
erasure
• No history 0 —
• History exists • Displays the total number of To erase the history, set the
malfunctions, including the engine stop switch to “ ”.
current malfunction, that
have occurred since the
history was last erased.
(For example, if there have
been three malfunctions,
“03” is displayed.)
63 Malfunction code reinstate-
ment
(for fault code No. 24 only)
• No malfunction code 00 —
• Malfunction code exists Fault code 24 To reinstate, set the engine
• (If more than one code stop switch from “ ” to
number is detected, the dis- “ ”.
play alternates every two
seconds to show all the de-
tected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
70 Control number 0–255 —
7-38
Actuator operation table

Diag-
nostic
Item Actuation Checking method
code
No.
Actuates the cylinder-#1 left
or right ignition coil five times Check the spark five times.
Cylinder-#1 left or right ig-
30 at one-second intervals. • Connect an ignition
nition coil
Illuminates the engine trou- checker.
ble warning light.
nition coil
ble warning light.
nition coil
ble warning light.
nition coil
ble warning light.
Actuates the injector #1 five
times at one-second inter-
Check the operating sound
36 Injector #1 vals.
of the injector #1 five times.
Illuminates the engine trou-
ble warning light.
Actuates the injector #2 five
times at one-second inter-
37 Injector #2 vals.
of the injector #2 five times.
ble warning light.
Actuates the fuel pump relay
five times at one-second in-
tervals.
ble warning light.
50 Fuel pump relay of the fuel pump relay five
(The engine trouble warning
times.
light is OFF when the relay is
ON, and the engine trouble
warning light is ON when the
relay is OFF).
Actuates the headlight relay
for five cycles of five sec-
onds. (ON 2 seconds, OFF 3 Check the operating sound
52 Headlight relay seconds) of the headlight relay five
Illuminates the engine trou- times.
ble warning light and head-
light.
7-39
Diag-
nostic
Item Actuation Checking method
code
No.
Actuates and fully closes the
ISC valve, then opens it to
the standby opening position
when the engine is started.
The ISC unit vibrates when
54 ISC valve This operation takes approxi-
the ISC valve operates.
mately 12 seconds until it is
completed.
ble warning light.
EAS27460
TROUBLESHOOTING DETAILS
This section describes the measures per fault code number displayed on the meter. Check and service
the items or components that are the probable cause of the malfunction following the order given.
After the check and service of the malfunctioning part has been completed, reset the meter display ac-
cording to the reinstatement method.
Fault code No.:
Code number displayed on the meter when the engine failed to work normally. Refer to “Self-Diagnostic
Function table”.
Diagnostic code No.:
Diagnostic code number to be used when the diagnostic mode is operated. Refer to “DIAGNOSTIC
MODE” on page 7-33.
7-40
Fault code No. 12 Symptom No normal signals are received from the crankshaft posi-
tion sensor.
Diagnostic code No. — —
Order Item/components and probable Check or maintenance job Reinstatement
cause method
1 Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the
tion sensor. engine.
2 Connections • Check the coupler for any pins
• Crankshaft position sensor coupler that may be pulled out.
• Main wire harness ECU coupler • Check the locking condition of
the coupler.
• If there is a malfunction, repair it
and connect the coupler se-
curely.
3 Open or short circuit in wire harness. • Repair or replace if there is an
open or short circuit.
• Between the crankshaft position
sensor coupler and ECU cou-
pler.
(gray–gray)
(black/blue–black/blue)
4 Defective crankshaft position sensor. • Replace if defective.
CRANKSHAFT POSITION
SENSOR” on page 7-85.
7-41
Fault code No. 13 Symptom Intake air pressure sensor: open or short circuit detected.
Diagnostic code No. 03 Intake air pressure sensor
cause method
1 Connections • Check the coupler for any pins Turning the
• Intake air pressure sensor coupler that may be pulled out. main switch to
• Main wire harness ECU coupler • Check the locking condition of “ON”.
the coupler.
curely.
• Between intake air pressure
pler.
(pink/white–pink/white)
(blue–blue)
3 Defective intake air pressure sensor. • Execute the diagnostic mode.
(Code No.03)
• Replace if defective.
Refer to “CHECKING THE IN-
TAKE AIR PRESSURE SEN-
SOR” on page 7-92.
7-42
Fault code No. 14 Symptom Intake air pressure sensor: hose system malfunction
(clogged or detached hose).
Diagnostic code No. 03 Intake air pressure sensor
cause method
1 Intake air pressure sensor hose • Check the intake air pressure Starting the en-
sensor hose condition. gine and oper-
• Repair or replace the sensor ating it at idle.
hose.
2 Intake air pressure sensor malfunction • Check and repair the connec-
at intermediate electrical potential. tion.
• Replace it if there is a malfunc-
tion.
• Intake air pressure sensor coupler that may be pulled out.
the coupler.
curely.
4 Defective intake air pressure sensor. • Execute the diagnostic mode.
(Code No.03)
TAKE AIR PRESSURE SEN-
7-43
Fault code No. 15 Symptom Throttle position sensor: open or short circuit detected.
Diagnostic code No. 01 Throttle position sensor
cause method
1 Installed condition of throttle position • Check for looseness or pinch- Turning the
sensor. ing. main switch to
• Check that the sensor is in- “ON”.
stalled in the specified position.
• Throttle position sensor coupler that may be pulled out.
• Sub-wire harness 2 coupler the coupler.
curely.
3 Open or short circuit in wire harness • Repair or replace if there is an
and/or sub lead. open or short circuit.
• Between throttle position sen-
sor coupler and ECU coupler.
(blue–blue)
(yellow–yellow)
(black–black)
4 Throttle position sensor lead wire • Check for open circuit and re-
open circuit output voltage check. place the throttle position sen-
sor.
(black–yellow)
Open circuit Output voltage
item
Ground wire 5V
open circuit
Output wire 0V
open circuit
Power supply 0V
wire open cir-
cuit
5 Defective throttle position sensor. • Execute the diagnostic mode.
(Code No.01)
THROTTLE POSITION SEN-
7-44
Fault code No. 17 Symptom EXUP servo motor circuit: open or short circuit detected.
Diagnostic code No. 53 EXUP servo motor
cause method
• EXUP servo motor coupler that may be pulled out. main switch to
the coupler.
curely.
• Between servo motor coupler
and ECU coupler.
(blue–blue)
(white/red–white/red)
3 Defective EXUP servo motor (potenti- • Execute the diagnostic mode.
ometer circuit). (Code No.53)
EXUP SERVO MOTOR” on
page 7-91.
7-45
Fault code No. 18 Symptom EXUP servo motor is stuck.

Diagnostic code No. 53 EXUP servo motor
cause method
• EXUP servo motor coupler that may be pulled out. main switch to
the coupler. It takes 120
• If there is a malfunction, repair it seconds at the
and connect the coupler se- maximum be-
curely. fore the origi-
2 Open or short circuit in wire harness. • Repair or replace if there is an nal state
open or short circuit. returns.
• Between the EXUP servo motor
coupler and the ECU coupler.
(black/green–black/green)
(black/red–black/red)
3 Defective EXUP servo motor. • Execute the diagnostic mode.
(Code No.53)
EXUP SERVO MOTOR” on
page 7-91.
4 Defective EXUP valve, pulley, cables. Replace if defective.
Fault code No. 19 Symptom A break or disconnection of the blue/black lead of the
ECU is detected.
Diagnostic code No. 20 Sidestand switch
cause method
1 Connections • Execute the diagnostic mode. If the transmis-
• Main wire harness ECU coupler (Code No.20) sion is in gear,
• Check the coupler for any pins retracting the
that may be pulled out. sidestand.
• Check the locking condition of If the transmis-
the coupler. sion is in neu-
• If there is a malfunction, repair it tral,
and connect the coupler se- reconnecting
curely. the wiring.
• Between ECU and blue/black
lead.
3 Defective sidestand switch. • Replace if defective.
7-46
Fault code No. 22 Symptom Air temperature sensor: open or short circuit detected.
Diagnostic code No. 05 Air temperature sensor
cause method
1 Installed condition of air temperature Check for looseness or pinching. Turning the
sensor. main switch to
2 Connections • Check the coupler for any pins “ON”.
• Air temperature sensor coupler that may be pulled out.
the coupler.
curely.
• Between air temperature sen-
sor coupler and ECU coupler.
(brown/white–brown/white)
4 Defective air temperature sensor. • Execute the diagnostic mode.
(Code No.05)
Refer to “CHECKING THE AIR
TEMPERATURE SENSOR” on
page 7-92.
7-47
Fault code No. 24 Symptom No normal signal is received from the O2 sensor.

cause method
1 Installed state of O2 sensor. Check for looseness or pinching. Starting the en-
gine and oper-
2 Connections • Check the coupler for any pins ating it at idle.
• O2 sensor coupler that may be pulled out.
the coupler.
curely.
• Between O2 sensor coupler and
ECU coupler.
(gray/white–gray/white)
(red/blue–red/blue)
(gray/green–gray/green)
4 Check fuel pressure. • Refer to “THROTTLE BODIES”
on page 6-6.
5 Defective O2 sensor. • Replace if defective.
7-48
Fault code No. 28 Symptom Engine temperature sensor: open or short circuit detect-
ed.
Diagnostic code No. 11 Engine temperature sensor
cause method
1 Installed state of engine temperature Check for looseness or pinching. Turning the
sensor. main switch to
2 Connections • Check the coupler for any pins “ON”.
• Engine temperature sensor coupler that may be pulled out.
• Sub-wire harness 2 coupler the coupler.
curely.
• Between engine temperature
pler.
(brown–brown)
(black–black)
4 Defective engine temperature sensor. • Execute the diagnostic mode.
(Code No.11)
Refer to “CHECKING THE EN-
GINE TEMPERATURE SEN-
7-49
Fault code No. 30 Symptom The vehicle has overturned.

Diagnostic code No. 08 Lean angle sensor
cause method
1 The vehicle has overturned. Raise the vehicle upright. Turning the
2 Installed condition of the lean angle Check for looseness or pinching. main switch to
sensor. “ON” (however,
the engine can-
3 Connections • Check the coupler for any pins not be restarted
• Lean angle sensor coupler that may be pulled out. unless the main
• Main wire harness ECU coupler • Check the locking condition of switch is first
the coupler. turned “OFF”).
curely.
4 Defective lean angle sensor. • Execute the diagnostic mode.
(Code No.08)
LEAN ANGLE SENSOR” on
page 7-86.
7-50
Fault code No. 33 Symptom Malfunction detected in the primary wire of the cylinder-#1
left or right ignition coil.
Diagnostic code No. 30, 32 Cylinder-#1 left or right ignition coil
cause method
1 Connections • Check the connector and cou- Starting the en-
• Cylinder-#1 left or right ignition coil pler for any pins that may be gine and oper-
connector (primary coil side) pulled out. ating it at idle.
the connector and coupler.
curely.
• Between cylinder-#1 left or right
ignition coil connector and ECU
coupler/main wire harness.
(black/red–blue/red)
(orange–orange)
3 Defective cylinder-#1 left or right igni- • Execute the diagnostic mode.
tion coil. (Code No.30 or 32)
• Test the primary and secondary
coils for continuity.
Refer to “CHECKING THE IG-
NITION COILS” on page 7-85.
7-51
cause method
• Sub-wire harness 3 coupler the connector and coupler.
curely.
(gray/red–gray/red)
7-52
cause method
the connector and coupler.
curely.
(orange–orange)
7-53
cause method
• Sub-wire harness 3 coupler the connector and coupler.
curely.
(gray/red–gray/red)
7-54
Fault code No. 37 Symptom Engine speed is high when the engine is idling.
Diagnostic code No. 54 ISC valve
cause method
1 ECU fuse is blown. • Check the ECU fuse. ISC valve re-
Refer to “CHECKING THE turns to its orig-
FUSES” on page 7-77. inal position by
2 Throttle valve does not fully close. • Check the throttle bodies. turning the
Refer to “THROTTLE BODIES” main switch to
on page 6-6. “ON” and back
• Check the throttle cables. to “OFF”.
Refer to “ADJUSTING THE Reinstated if
THROTTLE CABLE FREE the engine idle
PLAY” on page 3-8. speed is within
specification af-
3 ISC valve is stuck fully open due to • Check that the ISC unit hose is ter starting the
disconnected ISC unit hose or cou- not disconnected. engine.
pler. (High engine idle speed is de- • Check that the ISC unit coupler
tected with the ISC valve stuck fully is not disconnected.
open even though signals for the valve • The ISC valve is stuck fully
to close are continuously being trans- open if it does not operate when
mitted by the ECU.) the main switch is turned “OFF”.
(Touch the ISC unit with your
hand and check if it is vibrating
to confirm if the ISC valve is op-
erating.)
4 ISC valve is not moving correctly. • Execute the diagnostic mode.
(Code No.54)
• After the ISC valve is fully
closed, it opens to the standby
opening position when the en-
gine is started. This operation
takes approximately 12 sec-
onds. Start the engine. If the er-
ror recurs, replace the throttle
body assembly.
7-55
Fault code No. 39 Symptom Fuel injector: open or short circuit detected.
Diagnostic code No. 36, 37 Fuel injector
cause method
1 Connections • Check the couplers for any pins Start the en-
• Fuel injector coupler that may have pulled out. gine and let it
• Wire harness ECU coupler • Check the locking condition of idle for approxi-
the couplers. mately 5 sec-
• If there is a malfunction, repair it onds.
curely.
and/or injector sub-wire harness. open or short circuit.
• Between rear cylinder injector
coupler and ECU coupler.
(gray–gray)
(white–red/blue)
• Between front cylinder injector
(green–green)
(white–red/blue)
3 Defective fuel injector. • Execute the diagnostic mode.
(Code No.36, 37)
JECTORS” on page 6-14.
7-56
Fault code No. 41 Symptom Lean angle sensor: open or short circuit detected.
Diagnostic code No. 08 Lean angle sensor
cause method
• Lean angle sensor coupler that may be pulled out. main switch to
the coupler.
curely.
2 Open or short circuit in lead wire. • Repair or replace if there is an
• Between lean angle sensor
(blue–blue)
(yellow/green–yellow/green)
3 Defective lean angle sensor. • Execute the diagnostic mode.
(Code No.08)
LEAN ANGLE SENSOR” on
page 7-86.
7-57
Fault code No. 42 Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
Diagnostic code No. A 07 Speed sensor
B 21 Neutral switch
cause method
A-1 Connections • Check the coupler for any pins Starting the en-
• Speed sensor coupler that may be pulled out. gine, and acti-
• Main wire harness ECU coupler • Check the locking condition of vating the
the coupler. vehicle speed
• If there is a malfunction, repair it sensor by oper-
and connect the coupler se- ating the vehi-
curely. cle at 20 to 30
A-2 Open or short circuit in speed sensor • Repair or replace if there is an km/h.
lead. open or short circuit.
• Between speed sensor coupler
and ECU coupler.
(blue–blue)
(white/yellow–white/yellow)
A-3 Gear for detecting vehicle speed has • Replace if defective.
broken. Refer to “TRANSFER GEAR
CASE” on page 5-87.
A-4 Defective speed sensor. • Execute the diagnostic mode.
(Code No.07)
SPEED SENSOR” on page
7-90.
7-58
Fault code No. 42 Symptom A. No normal signals are received from the speed sensor.
B. Open circuit is detected in the neutral switch.
Diagnostic code No. A 07 Speed sensor
B 21 Neutral switch
cause method
B-1 Connections • Check the coupler for any pins Starting the en-
• Neutral switch coupler that may be pulled out. gine, and acti-
• Main wire harness ECU coupler • Check the locking condition of vating the
the coupler. vehicle speed
• If there is a malfunction, repair it sensor by oper-
and connect the coupler se- ating the vehi-
curely. cle at 20 to 30
B-2 Open circuit in neutral switch lead. • Repair or replace if there is an km/h.
open circuit.
• Between neutral switch coupler
and relay unit coupler (fuel
pump relay).
(sky blue–sky blue)
• Between relay unit coupler and
main switch.
(blue/yellow–blue/yellow)
• Between main switch and ECU
coupler.
(blue/black–blue/black)
B-3 Faulty shift drum (neutral detection ar- • Replace if defective.
ea). Refer to “TRANSMISSION” on
page 5-113.
B-4 Defective neutral switch. • Execute the diagnostic mode.
(Code No.21)
7-59
Fault code No. 43 Symptom The ECU is unable to monitor the battery voltage (an open
or short circuit in the line to the ECU).
Diagnostic code No. 09 Fuel system voltage
cause method
1 Connections • Check the coupler for any pins Starting the en-
• Relay unit coupler (fuel pump relay) that may be pulled out. gine and oper-
• Main wire harness ECU coupler • Check the locking condition of ating it at idle.
the coupler.
curely.
2 Open or short circuit in the wire har- • Repair or replace if there is an
ness. open or short circuit.
• Between relay unit coupler (fuel
pump relay) and ECU coupler.
(blue/red–blue/red)
(red/blue–red/blue)
pump relay) and battery termi-
nal.
(red–red)
pump relay) and engine stop
switch coupler.
(black/red–black/red)
3 Malfunction or open circuit in relay • Execute the diagnostic mode.
unit (fuel pump relay). (Code No. 09)
• If there is no malfunction with
the relay unit (fuel pump relay),
replace the ECU.
Fault code No. 44 Symptom Error is detected while reading or writing on EEPROM (CO
adjustment value).
Diagnostic code No. 60 EEPROM improper cylinder indication
cause method
1 Malfunction in ECU. • Execute the diagnostic mode. Turning the
(Code No. 60) main switch to
1. Check the faulty cylinder. (If “ON”.
multiple cylinders are defec-
tive, the number of the faulty
cylinders appears alternate-
ly at 2-second intervals.)
• Replace ECU if defective.
7-60
Fault code No. 46 Symptom Power supply to the fuel injection system is not normal.
cause method
1 Connections • Check the coupler for any pins Starting the en-
• Main wire harness ECU coupler that may be pulled out. gine and oper-
• Check the locking condition of ating it at idle.
the coupler.
curely.
2 Faulty battery. • Replace or charge the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY” on
page 7-78.
3 Malfunction in rectifier/regulator • Replace if defective.
Refer to “CHARGING SYS-
TEM” on page 7-13.
• Between battery and main fuse.
(red–red)
• Between main fuse and main
switch.
(red–red)
• Between main switch and igni-
tion fuse.
(brown/blue–brown/blue)
• Between ignition fuse and ECU.
(red/white–red/white)
Fault code No. 50 Symptom Faulty ECU memory. (When this malfunction is detected in
the ECU, the fault code number might not appear on the
meter.)
cause method
1 Malfunction in ECU. Replace the ECU. Turning the
TIP main switch to
Do not perform this procedure “ON”.
with the main switch turned to
“ON”.
7-61
Fault code No. Er-1 Symptom No signals are received from the ECU.
cause method
• Main wire harness ECU coupler that may be pulled out. main switch to
• Main wire harness meter assembly • Check the locking condition of “ON”.
coupler the coupler.
curely.
• Between meter assembly cou-
pler and ECU coupler.
(yellow/blue–yellow/blue)
3 Malfunction in meter assembly. Replace the meter assembly.
4 Malfunction in ECU. Replace the ECU.
Fault code No. Er-2 Symptom No signals are received from the ECU within the specified
duration.
cause method
curely.
7-62
Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly.
cause method
curely.
Fault code No. Er-4 Symptom Non-registered data has been received from the meter.
cause method
curely.
7-63
7-64
EAS27560
EAS27550
L2 B/R3
L1 R1 Sb/W
R1 L1 B/R3 L/W R/L2
(GRAY) (BLACK) L/R
4 R/L2
5
R1 R1 R2
W2 W2 R2 R2
1 2 4 R4 R/W B/Y2 L/Y1 Sb L/G A
W3 W3 B4 B1 B2 B3 G/W R/L1
L/W
R2 Sb R/L2 W2
R/L1 R/L3 W1 L/R 4 B/R4 4 B/R1 B/R1
R3 R1 14 25
B G/W B2 O2 Ch Dg
B1 Sb Dg Ch
B 15 16
B/R B/R3 B/R2
B2 4 R/L4 R/L4 29
B1 (GRAY)
B/R3
CIRCUIT DIAGRAM

13 O1 O1
4 B/Y2 B
R/B R/B
29
B/Y1 L/W B/R2
R/W4 G/R2 G/R2
W1 W2 B B W2 W1
29
R1 Br Br B Br Br
R3 Br B 17 B/R
R1 G/R1 G/R1
FUEL PUMP SYSTEM
3 6 L Y B1 W1 G 29
ON L3 Y Y C Y Y
R2 R2 18
8 (GRAY)
R/W2
L/B L/Y 24 B1
Br/L 19 B/L2 W2 Gy
(RED) B B (BLACK)
31 (DARK GRAY)
Br/L1 L/B B/L4
L/Y3 L/B L/Y1 B4 B3
9 20 B R/L3
Br/L1 L4
(RED) (BLACK)
Gy/W R/L3
Y/G Y/G B B
L/Y3 21 B/L3 W L
32
(BLACK)
4 Gy Gy/B Gy/B Y/L
B5 22 B/G B/G
B2 B/R B/R
R/W3 L1
B/L4 L5 W/R B/L2
L5 B/G B/R
B1 4 33
L3 W/Y1 W L B B/L6
L3 (BLACK)
B/L6 23 B/L2
B B4 B3 R/G R/G
14 14 14 W/Y2 W/G W/G 34 Br/L R/B2 Br/Y
Y/B
4 W/Y2
R/B1R/B2
W/Y3
70 B1B2B/W2 B/W1 R/B3 R/B2 R/B1 R
R R/B
7-65
14
71 R/B3
R4 R/Y R/B2
R/B1
R
Br/L1 72 B/W1
B/W2
Br/L3 Br/L3 R/W1
4 Br/L2 B/W5 B/W3
14 Sb/W
B/W
4 Br4 Br4
4 Br 35 Sb
Br P1
Br B/W
R/Y (BLACK) 46
73 Br Y/B 49
W/Y3
74 48 Br/W Br2
B G/W
4 G/Y
Br/W B3 Y/R R/W3
37 G
75 G/L1 P2
Br3
B3 B4
G Y Y G G
G/L1 G/L
52 53 54 55 38
69 (GREEN) (GREEN)
(L) PUSH G B
R/W
Y1 Br3 60 Y3 Br2 B/R2 L/W G/L3 N 39 45
(R)
B2 B1
L/G Br Y1 62 63 64 (BLACK) 40 B2 G
51 B4
B/R2 R/W (BLACK)
B1 Y/L G/W G/Y
4 B/W4 G B
B3 B2 Ch3
B1 B2 (BLACK)
Y L Y3 (BLACK)
L 44
Ch A Ch
B3 4 68 Dg A Dg Dg3
L/B
B
67 Ch Dg
B 59 B/W4
L Ch Dg
B B B G
66 65 L/B B B5 L/B Ch L 14 Dg L
Y2 B2
B B B B5 B
Y L L Y
L Ch Dg B2 B3 B4
B B L1 Ch2 L3 Dg2
B B B B3 B4
B2
B5 14 B4
B4
B A B
FUEL PUMP SYSTEM
FUEL PUMP SYSTEM
3. Main switch
4. Joint
5. Main fuse
6. Battery
10.Relay unit
12.Fuel pump relay
14.Joint connector
16.Fuel pump
72.ECU fuse
74.Ignition fuse
7-66
FUEL PUMP SYSTEM
EAS27570
TROUBLESHOOTING
If the fuel pump fails to operate.
TIP
1. Rider seat
2. Tool kit tray
4. Left side cover

(Main, fuel injection system, ECU,
and ignition) Replace the fuse(s).
ES” on page 7-77.
OK ↓
page 7-78.
OK ↓
OK ↓
4. Check the engine stop switch. NG →
OK ↓
5. Check the relay unit (fuel pump re- NG →
lay).
Replace the relay unit.
Refer to “CHECKING THE RE-
OK ↓
6. Check the fuel pump. NG →
Refer to “CHECKING THE FUEL Replace the fuel pump assembly.
PUMP” on page 7-91.
OK ↓
7. Check the entire fuel pump system NG →
wiring. Properly connect or repair the fuel pump
page 7-65.
OK ↓
Replace the ECU.
7-67
FUEL PUMP SYSTEM
7-68
ELECTRICAL COMPONENTS
EAS27970
4 6
1
5
2
7 8
10
16
11
15 12
14
13
7-69
1. Cylinder-#2 right ignition coil (for XV19S(C)/

XV19CTS(C))
2. Cylinder-#2 left ignition coil (for XV19S(C)/
XV19CTS(C))
3. Fuel sender
4. Engine temperature sensor
5. Cylinder-#1 left ignition coil (for XV19S(C)/
XV19CTS(C))
Cylinder-#2 right ignition coil (for XV19CS(C)/
XV19C(C))
6. Cylinder-#1 right ignition coil (for XV19S(C)/
XV19CTS(C))
Cylinder-#1 right ignition coil (for XV19CS(C)/
XV19C(C))
7. Cylinder-#2 left ignition coil (for XV19CS(C)/
XV19C(C))
8. Cylinder-#1 left ignition coil (for XV19CS(C)/
XV19C(C))
11. Speed sensor
12. Rectifier/regulator
13. Neutral switch
14. Horn 2
15. Horn 1
7-70
3
2
4
16
9
7
10
11
15 6
12
14
13
7-71

2. Main switch
5. Fuse box
6. Starter relay
8. Battery
9. Turn signal relay
10. Headlight relay
11. Relay unit
12. Diode (for XV19S(C)/ XV19CTS(C))
13. Main fuse
14. Lean angle sensor
7-72
EAS27980
CHECKING THE SWITCHES
1 R Br/L L/Y L/B

R
ON
Br/L OFF
A L/Y
B
L/B L/Y
L/B
(RED)
13 Y G
Ch Br/W Dg B Y/R G/L
(BLUE) B B 2
R/W B/R
(L)
B B
R/W B/R
G/Y G/B
(R) G/L L/B
(GRAY)
3
P B L/W W/B
12 Y/R
L/W W/B
G/Y G/B (GRAY)

(BLACK)
PUSH
Ch Dg
Br/W
4
(GRAY) L/B G/L
11
Y G/L G
10 5
Br Y
B P
9 L/Y B/Y
B
B
6
B
8 7 B
B B B B
(BLACK) (BLACK)
7-73
1. Main switch
2. Engine stop switch
3. Start switch
4. Accessory light switch
5. Front brake light switch
6. Neutral switch
7. Sidestand switch
9. Clutch switch
10. Horn switch
11. Dimmer switch
12. Select switch
13. Turn signal switch
7-74
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown, blue/yellow and blue/black when the switch is
set to “ON”.
b
R Br L/Y L/B
ON
a
OFF
R L/Y
Br L/B
7-75
EAS27990
1. Remove:
CHECKING THE BULBS AND BULB
• Bulb
SOCKETS EW1D71009
TIP WARNING
Do not check any of the lights that use LEDs. Since headlight bulbs get extremely hot,
keep flammable products and your hands
Check each bulb and bulb socket for damage or
away from them until they have cooled
wear, proper connections, and also for continuity
down.
between the terminals.
Damage/wear → Repair or replace the bulb, EC1D71006
NOTICE
bulb socket or both.
Improperly connected → Properly connect. • Be sure to hold the socket firmly when re-
No continuity → Repair or replace the bulb, bulb moving the bulb. Never pull the lead, other-
socket or both. wise it may be pulled out of the terminal in
the coupler.
Types of bulbs • Avoid touching the glass part of a headlight
The bulbs used on this vehicle are shown in the bulb to keep it free from oil, otherwise the
illustration. transparency of the glass, the life of the
• Bulbs “a” and “b” are used for the headlights bulb, and the luminous flux will be adverse-
and usually use a bulb holder that must be de- ly affected. If the headlight bulb gets soiled,
tached before removing the bulb. The majority thoroughly clean it with a cloth moistened
of these types of bulbs can be removed from with alcohol or lacquer thinner.
their respective socket by turning them coun- 2. Check:
terclockwise. • Bulb (for continuity)
• Bulbs “c” are used for turn signal and tail/brake (with the pocket tester)
lights and can be removed from the socket by No continuity → Replace.
pushing and turning the bulb counterclockwise.
• Bulbs “d” and “e” are used for meter and indi- Pocket tester
cator lights and can be removed from their re- 90890-03112
spective socket by carefully pulling them out. Analog pocket tester
YU-03112-C
TIP
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“2”, and check the continuity.
b. Connect the positive tester probe to terminal
“1” and the negative tester probe to terminal
“3”, and check the continuity.
c. If either of the readings indicate no continuity,
replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Checking the condition of the bulbs

bulbs.
7-76
TIP
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
YU-03112-C
b. If the pocket tester indicates “∞”, replace the

fuse.
Checking the condition of the bulb sockets ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
The following procedure applies to all of the bulb 3. Replace:
sockets. • Blown fuse
1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Bulb socket (for continuity) a. Turn the main switch to “OFF”.
(with the pocket tester) b. Install a new fuse of the correct amperage
No continuity → Replace. rating.
c. Set on the switches to verify if the electrical
Pocket tester circuit is operational.
90890-03112 d. If the fuse immediately blows again, check
Analog pocket tester the electrical circuit.
YU-03112-C
For XV19S(C)/ XV19CTS(C)
TIP Amperage
Fuses Q’ty
Check each bulb socket for continuity in the rating
same manner as described in the bulb section;
Main 50 A 1
however, note the following.
Ignition 20 A 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket. Headlight 20 A 1
b. Connect the pocket tester probes to the re- Fuel injection system 15 A 1
spective leads of the bulb socket.
Signaling system 15 A 1
c. Check the bulb socket for continuity. If any of
the readings indicate no continuity, replace ECU 15 A 1
the bulb socket. Backup (odometer and
5A 1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ clock)
EAS28000 Auxiliary DC connector 5A 1
CHECKING THE FUSES
Spare 20 A 1
The following procedure applies to all of the fus-
es. Spare 15 A 1
EC1D71019
Spare 5A 1
NOTICE
To avoid a short circuit, always turn the main For XV19CS(C)/ XV19C(C)
switch to “OFF” when checking or replacing
a fuse. Amperage
Fuses Q’ty
rating
1. Remove:
• Rider seat Main 50 A 1
Refer to “GENERAL CHASSIS” on page 4-1. Ignition 20 A 1
2. Check: Headlight 20 A 1
• Fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Fuel injection system 15 A 1
a. Connect the pocket tester to the fuse and Signaling system 15 A 1
check the continuity.
ECU 15 A 1
7-77
Amperage • Drink large quantities of water or milk fol-

Fuses Q’ty lowed with milk of magnesia, beaten egg or
rating
vegetable oil. Get immediate medical atten-
Backup (odometer and tion.
3A 1
clock) ECA1D7K001
Auxiliary DC connector 3A 1 NOTICE

Spare 20 A 1 • This is a VRLA (Valve Regulated Lead Acid)
Spare 15 A 1 battery. Never remove the sealing caps be-
cause the balance between cells will not be
Spare 3A 1 maintained and battery performance will
EWA13310 deteriorate.
WARNING • Charging time, charging amperage and
Never use a fuse with an amperage rating charging voltage for an VRLA (Valve Regu-
other than that specified. Improvising or us- lated Lead Acid) battery are different from
ing a fuse with the wrong amperage rating those of conventional batteries. The VRLA
may cause extensive damage to the electri- (Valve Regulated Lead Acid) battery should
cal system, cause the lighting and ignition be charged according to the instructions
systems to malfunction and could possibly for the charging method. If the battery is
cause a fire. overcharged, the electrolyte level will drop
considerably. Therefore, take special care
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
when charging the battery.
4. Install:
• Rider seat TIP
Refer to “GENERAL CHASSIS” on page 4-1. Since VRLA (Valve Regulated Lead Acid) bat-
teries are sealed, it is not possible to check the
EAS28030
CHECKING AND CHARGING THE BATTERY charge state of the battery by measuring the
EWA13290 specific gravity of the electrolyte. Therefore, the
WARNING charge of the battery has to be checked by mea-
Batteries generate explosive hydrogen gas suring the voltage at the battery terminals.
and contain electrolyte which is made of poi- 1. Remove:
sonous and highly caustic sulfuric acid. • Rider seat
Therefore, always follow these preventive Refer to “GENERAL CHASSIS” on page 4-1.
measures: 2. Remove:
• Wear protective eye gear when handling or • ECU band “1”
working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment, 1
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye 3. Remove:
injury. • Coupler tray “1”
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
7-78
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20–30%
1
4. Disconnect:
• Battery leads
(from the battery terminals)
ECA13640
NOTICE
First, disconnect the negative battery lead A. Open-circuit voltage (V)
“1”, and then positive battery lead “2”. B. Charging time (hours)
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
1
D. These values vary with the temperature, the
condition of the battery plates, and the
electrolyte level.
5. Remove:
• Battery
6. Check:
• Battery charge
A. Open-circuit voltage (V)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery termi- B. Charging condition of the battery (%)
nals. C. Ambient temperature 20 °C (68 °F)
• Positive tester probe → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
positive battery terminal 7. Charge:
• Negative tester probe → • Battery
negative battery terminal
(refer to the appropriate charging method)
EWA13300
TIP WARNING
• The charge state of an VRLA (Valve Regulated Do not quick charge a battery.
Lead Acid) battery can be checked by measur-
ECA1D7K002
ing its open-circuit voltage (i.e., the voltage NOTICE
when the positive battery terminal is discon-
nected). • Never remove the VRLA (Valve Regulated
• No charging is necessary when the open-cir- Lead Acid) battery sealing caps.
cuit voltage equals or exceeds 12.8 V. • Do not use a high-rate battery charger
since it forces a high-amperage current
b. Check the charge of the battery, as shown in into the battery quickly and can cause bat-
the charts and the following example. tery overheating and battery plate damage.
7-79
• If it is impossible to regulate the charging TIP

current on the battery charger, be careful Voltage should be measured 30 minutes after
not to overcharge the battery. the engine is stopped.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be b. Connect a charger and ammeter to the bat-
done with the battery mounted on the vehi- tery and start charging.
cle, disconnect the negative battery lead TIP
from the battery terminal.) Set the charging voltage at 16–17 V. If the set-
• To reduce the chance of sparks, do not ting is lower, charging will be insufficient. If too
plug in the battery charger until the battery high, the battery will be over-charged.
charger leads are connected to the battery.
• Before removing the battery charger lead c. Make sure that the current is higher than the
clips from the battery terminals, be sure to standard charging current written on the bat-
tery.
turn off the battery charger.
• Make sure the battery charger lead clips are TIP
in full contact with the battery terminal and If the current is lower than the standard charging
that they are not shorted. A corroded bat- current written on the battery, set the charging
tery charger lead clip may generate heat in voltage adjust dial at 20–24 V and monitor the
the contact area and a weak clip spring may amperage for 3–5 minutes to check the battery.
cause sparks.
• If the battery becomes hot to the touch at • Standard charging current is reached
Battery is good.
any time during the charging process, dis-
• Standard charging current is not reached
connect the battery charger and let the bat- Replace the battery.
tery cool before reconnecting it. Hot
batteries can explode! d. Adjust the voltage so that the current is at the
• As shown in the following illustration, the standard charging level.
open-circuit voltage of an VRLA (Valve e. Set the time according to the charging time
Regulated Lead Acid) battery stabilizes suitable for the open-circuit voltage.
about 30 minutes after charging has been f. If charging requires more than 5 hours, it is
completed. Therefore, wait 30 minutes after advisable to check the charging current after
charging is completed before measuring a lapse of 5 hours. If there is any change in
the open-circuit voltage. the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
A. Open-circuit voltage (V) Charging method using a constant volt-
B. Time (minutes) age charger
C. Charging a. Measure the open-circuit voltage prior to
D. Ambient temperature 20 °C (68 °F) charging.
E. Check the open-circuit voltage. TIP
Voltage should be measured 30 minutes after
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the engine is stopped.
Charging method using a variable-current
(voltage) charger b. Connect a charger and ammeter to the bat-
a. Measure the open-circuit voltage prior to tery and start charging.
charging.
7-80
c. Make sure that the current is higher than the 11.Lubricate:

standard charging current written on the bat- • Battery terminals
tery.
TIP
Dielectric grease
If the current is lower than the standard charging
current written on the battery, this type of battery 12.Install:
charger cannot charge the VRLA (Valve Regu- • Coupler tray
lated Lead Acid) battery. A variable voltage • ECU band
charger is recommended. TIP
d. Charge the battery until the battery’s charg- Make sure the leads are routed correctly.
ing voltage is 15 V.
13.Install:
TIP • Rider seat
Set the charging time at 20 hours (maximum). Refer to “GENERAL CHASSIS” on page 4-1.
e. Measure the battery open-circuit voltage after EAS28040
leaving the battery unused for more than 30 CHECKING THE RELAYS
minutes. Check each switch for continuity with the pocket
12.8 V or more --- Charging is complete. tester. If the continuity reading is incorrect, re-
12.7 V or less --- Recharging is required. place the relay.
Under 12.0 V --- Replace the battery.
Pocket tester
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 90890-03112
8. Install: Analog pocket tester
• Battery YU-03112-C
1. Disconnect the relay from the wire harness.
9. Connect:
2. Connect the pocket tester (Ω × 1) and battery
• Battery leads
(12 V) to the relay terminals as shown.
(to the battery terminals)
ECA13630
Check the relay operation.
NOTICE Out of specification → Replace.
First, connect the positive battery lead “1”,
Starter relay
and then the negative battery lead “2”.
3
TIP
Be sure to route the negative battery lead to- R
wards the front of the vehicle and to install the
negative terminal cover “3” securely. R
R/Y L
2 B
2 1
3 4
1. Positive battery terminal
2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
1
10.Check: Result
• Battery terminals Continuity
(between “3” and “4”)
Dirt → Clean with a wire brush.
7-81
Relay unit (starting circuit cut-off relay) 2. Negative battery terminal

3 1 2 4 +
Result
Continuity
ET1D71011
CHECKING THE TURN SIGNAL RELAY

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

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

brown “1”
• Negative tester probe →
ground

Result
Continuity
Headlight relay b. Turn the main switch to “ON”.

3 c. Measure the turn signal relay input voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 +
2. Check:
• Turn signal relay output voltage
2 1 Out of specification → Replace.
Y/B Br
Turn signal relay output voltage
G/L
DC 12 V
R/Y
7-82
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the Continuity
turn signal relay terminal as shown. Positive tester probe → sky blue
“1”
Pocket tester Negative tester probe →
90890-03112 black/yellow “2”
Analog pocket tester No continuity
YU-03112-C Positive tester probe →
black/yellow “2”
• Positive tester probe → Negative tester probe → sky
brown/white “1” or yellow/red “2” blue “1”
• Negative tester probe → Continuity
ground Positive tester probe → sky blue
“1”
Negative tester probe →
blue/yellow “3”
No continuity
Positive tester probe →
blue/yellow “3”
Negative tester probe → sky
blue “1”
Continuity
Positive tester probe → sky blue
“1”
Negative tester probe → sky
b. Turn the main switch to “ON”. blue/white “4”
c. Measure the turn signal relay output voltage. No continuity
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Positive tester probe → sky
EAS28050
blue/white “4”
CHECKING THE DIODES Negative tester probe → sky
blue “1”
Relay unit (diode) Continuity
1. Check:
blue/green “5”
• Relay unit (diode) Negative tester probe →
Out of specification → Replace. blue/yellow “3”
No continuity
Pocket tester Positive tester probe →
90890-03112 blue/yellow “3”
Analog pocket tester Negative tester probe →
YU-03112-C blue/green “5”
TIP
The pocket tester or the analog pocket tester
readings are shown in the following table. 5 3 1 2 4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the relay unit from the wire har-
ness.
b. Connect the pocket tester (Ω × 1) to the relay
unit terminals as shown.
7-83
c. Check the relay unit (diode) for continuity.

d. Check the relay unit (diode) for no continuity. Minimum ignition spark gap
6.0 mm (0.24 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Diode (for XV19S(C)/ XV19CTS(C)) TIP

1. Check: If the ignition spark gap is within specification,
• Diode the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Pocket tester a. Disconnect the spark plug cap from the spark
90890-03112 plug.
Analog pocket tester b. Connect the ignition checker “1” as shown.
YU-03112-C
Ignition checker
90890-06754
TIP
Oppama pet-4000 spark checker
The pocket tester and the analog pocket tester YM-34487
readings are shown in the following table.
Continuity
Positive tester probe → red/yel-
low “1”
Negative tester probe →
red/white “2” or red/white “3”
No continuity
red/white “2” or red/white “3”
Negative tester probe → red/yel-
low “1”
2. Spark plug cap
c. Turn the main switch to “ON” and engine stop
2 3 switch to “ ”.
d. Measure the ignition spark gap “a”.
e. Crank the engine by pushing the start switch
R/W R/W “ ” and gradually increase the spark gap un-
til a misfire occurs.
R/Y
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28070
1 CHECKING THE SPARK PLUG CAPS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
spark plug caps.
a. Disconnect the diode from the wire harness.
1. Check:
b. Connect the pocket tester (Ω × 1) to the diode
• Spark plug cap resistance
terminals as shown.
c. Check the diode for continuity.
d. Check the diode for no continuity. Resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 10.0 kΩ
ET1D71012
CHECKING THE IGNITION SPARK GAP ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼

1. Check: a. Remove the spark plug cap from the spark
• Ignition spark gap plug lead.
Out of specification → Perform the ignition b. Connect the pocket tester (Ω × 1k) to the
system troubleshooting, starting with step 5. spark plug cap as shown.
Refer to “TROUBLESHOOTING” on page
7-4.
7-84
c. Measure the primary coil resistance.

Pocket tester ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-03112
Analog pocket tester 2. Check:
YU-03112-C • Secondary coil resistance
Secondary coil resistance

8.64–12.96 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
Pocket tester
c. Measure the spark plug cap resistance. 90890-03112
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YU-03112-C
EAS28100
CHECKING THE IGNITION COILS

The following procedure applies to all of the igni- • Negative tester probe →
tion coils. black/red “1”
1. Check:
spark plug lead “2”
• Primary coil resistance
Primary coil resistance

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

90890-03112 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS28120
YU-03112-C CHECKING THE CRANKSHAFT POSITION
SENSOR
• Positive tester probe → 1. Disconnect:
black/red “1” • Crankshaft position sensor coupler
(from the wire harness)
orange or gray/red “2”
2. Check:
• Crankshaft position sensor resistance
shaft position sensor.
Crankshaft position sensor resis-

tance
248–372 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 100) to the
crankshaft position sensor coupler as shown.
7-85
Pocket tester
90890-03112
YU-03112-C

gray “1”
black “2”
c. Turn the lean angle sensor to 65°.
d. Measure the lean angle sensor output volt-
age.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71013
CHECKING THE STARTER MOTOR

OPERATION
B Gy 1. Check:
• Starter motor operation
2 1
Does not operate → Perform the electric
b. Measure the crankshaft position sensor re- starting system troubleshooting, starting with
sistance. step 5.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Refer to “TROUBLESHOOTING” on page
EAS28130
7-10.
CHECKING THE LEAN ANGLE SENSOR ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1. Remove: a. Connect the positive battery terminal “1” and
• Lean angle sensor starter motor lead “2” with a jumper lead “3”.
EWA13810
2. Check: WARNING
• Lean angle sensor output voltage
• A wire that is used as a jumper lead must
have at least the same capacity of the bat-
Lean angle sensor output voltage tery lead, otherwise the jumper lead may
Less than 65°: 0.4–1.4 V burn.
More than 65°: 3.7–4.4 V • This check is likely to produce sparks,
therefore, make sure no flammable gas or
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ fluid is in the vicinity.
a. Connect the lean angle sensor coupler to the
wire harness.
b. Connect the pocket tester (DC 20 V) to the
lean angle sensor coupler as shown.
Pocket tester
90890-03112
YU-03112-C

yellow/green “1” b. Check the starter motor operation.
• Negative tester probe → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
black/blue “2”
EAS28150
CHECKING THE STATOR COIL

1. Disconnect:
• Stator coil coupler
(from the rectifier/regulator)
7-86
2. Check: b. Connect the pocket tester (DC 20 V) to the

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

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

white “1”
white “3” c. Start the engine and let it run at approximate-
ly 5000 r/min.
• Positive tester probe → d. Measure the charging voltage.
white “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Negative tester probe → EAS28180
white “3” CHECKING THE HORNS
1. Check:
• Horn resistance
Coil resistance
0.94–0.98 Ω
W W W ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the horn 1 connectors and horn 2
coupler from the horn terminals.
1 2 3 b. Connect the pocket tester (Ω × 1) to the horn
b. Measure the stator coil resistance. terminals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Pocket tester
EAS28170 90890-03112
CHECKING THE RECTIFIER/REGULATOR Analog pocket tester
1. Check: YU-03112-C
• Charging voltage
Out of specification → Replace the rectifi- • Positive tester probe →
er/regulator. horn terminal “1”
Charging voltage horn terminal “2”
14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the engine tachometer to the cylinder-#1
left spark plug lead or right spark plug lead.
7-87
A A
1 2
a b
B 1 2 B
a b
A. Horn 1 A. Horn 1
B. Horn 2 B. Horn 2
c. Measure the horn resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28210
2. Check: CHECKING THE ENGINE TEMPERATURE

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

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

tance
0.90–1.10 kΩ at 100 °C (212 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1 k) to the en-
gine temperature sensor terminals as shown.
Pocket tester
90890-03112
YU-03112-C
7-88

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

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

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ PUMP)
3. Install: 1. Drain the fuel.
• Engine temperature sensor 2. Disconnect:
• Fuel pump coupler
Engine temperature sensor (from the fuel pump)
20 Nm (2.0 m·kg, 14 ft·lb) 3. Remove:
T.
R.
• Fuel pump
ET1D71014 (from the sub-fuel tank)
CHECKING THE FUEL SENDER (FUEL 4. Check:
TANK) • Fuel sender resistance
1. Remove: Out of specification → Replace the fuel pump
• Fuel sender assembly.
(from the fuel tank)
2. Check: Fuel sender resistance
• Fuel sender resistance 0.90–2.05 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Fuel sender (fuel tank) a. Connect the pocket tester (Ω × 1) to the fuel
Sender unit resistance (full) sender terminals as shown.
9–11 Ω
Sender unit resistance (empty) Pocket tester
213.0–219.0 Ω 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C
a. Connect the pocket tester (Ω × 100) to the
fuel sender coupler as shown. • Positive tester probe →
green/white “1”
Pocket tester • Negative tester probe →
90890-03112 black “2”
YU-03112-C
7-89
Pocket tester
90890-03112
2 1 Analog pocket tester
G/W B
YU-03112-C
R/L B
white “1”
black “2”
b. Measure the fuel sender resistance.

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

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

SENSOR
1. Remove:
• Throttle position sensor
(from the throttle body)
2. Check:
1 • Throttle position sensor maximum resistance
Out of specification → Replace the throttle
position sensor.
Resistance
EAS28240 3.1–5.7 kΩ/blue-black
CHECKING THE SPEED SENSOR
1. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Speed sensor output voltage a. Connect the pocket tester (Ω × 1k) to the
Out of specification → Replace. throttle position sensor terminals as shown.
Output voltage reading cycle Pocket tester

0.6 V to 4.8 V to 0.6 V to 4.8 V 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ YU-03112-C
a. Connect the pocket tester (DC 20 V) to the
speed sensor coupler as shown. • Positive tester probe →
blue “1”
black “2”
7-90
• Positive battery lead →

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

mum resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Throttle position sensor
d. Check the fuel pump operation.
TIP
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
When installing the throttle position sensor, ad- EAS28360
just its angle properly. Refer to “ADJUSTING CHECKING THE EXUP SERVO MOTOR
THE THROTTLE POSITION SENSOR” on page 1. Check:
6-15. • EXUP servo motor operation
EAS28350
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CHECKING THE FUEL PUMP a. Disconnect the EXUP cables from the EXUP
EWA13850
servo motor pulley.
WARNING
b. Disconnect the EXUP servo motor coupler
Gasoline is extremely flammable and under from the wire harness.
certain circumstances there can be a danger c. Connect the battery leads to the EXUP servo
of an explosion or fire. Be extremely careful motor terminals as shown.
and note the following points:
For counterclockwise rotation “a”
• Stop the engine before refueling.
• Positive battery lead →
• Do not smoke, and keep away from open black/green “1”
flames, sparks, or any other source of fire. • Negative battery lead →
• If you do accidentally spill gasoline, wipe it black/red “2”
up immediately with dry rags. For clockwise rotation “b”
• If gasoline touches the engine when it is • Positive battery lead →
hot, a fire may occur. Therefore, make sure black/red “2”
the engine is completely cool before per- • Negative battery lead →
forming the following test. black/green “1”
1. Disconnect:
• Fuel pump coupler
(from the fuel pump) 1 2
2. Check: b
• Fuel pump operation
Faulty/rough movement → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the fuel tank. a L W/R B/L
B/G B/R
b. Put the end of the fuel hose “1” into an open

container.
c. Connect the battery (DC 12 V) to the fuel
d. Check that the EXUP servo motor pulley ro-
pump terminals as shown.
tates several times in directions “a” and “b”.
7-91
ECA14390
• Never subject the air temperature sensor to
NOTICE strong shocks. If the air temperature sen-
To prevent damaging the EXUP servo motor, sor is dropped, replace it.
perform this test within a few seconds of
2. Check:
connecting the battery.
• Air temperature sensor resistance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Out of specification → Replace.
EAS28410
CHECKING THE INTAKE AIR PRESSURE Air temperature sensor resis-

SENSOR tance
1. Check: 290–390 Ω at 80 °C (176 °F)
• Intake air pressure sensor output voltage
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace. a. Connect the pocket tester (Ω × 100) to the air
temperature sensor terminals as shown.
Intake air pressure sensor output
voltage Pocket tester
3.57–3.71 V 90890-03112
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (DC 20 V) to the in- YU-03112-C
take air pressure sensor coupler as shown.
Pocket tester
90890-03112 3
Analog pocket tester 1
YU-03112-C

pink/white “1” or pink/yellow 2
black/blue “2”
b. Immerse the air temperature sensor “1” in a
container filled with water “2”.
2 1 TIP
Make sure that the air temperature sensor termi-
nals do not get wet.
B/L P/W L
c. Place a thermometer “3” in the water.
d. Slowly heat the water, then let it cool down to
the specified temperature.
e. Measure the air temperature sensor resis-
tance.
b. Turn the main switch to “ON”. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
c. Measure the intake air pressure sensor out-
put voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ET1D71016
CHECKING THE AIR TEMPERATURE

SENSOR
1. Remove:
• Air temperature sensor
EW1D71004
WARNING
• Handle the air temperature sensor with
special care.
7-92
7-93
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
GENERAL INFORMATION ....................................................................... 8-1
STARTING FAILURES..............................................................................8-1
INCORRECT ENGINE IDLING SPEED .................................................... 8-1
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ........................... 8-2
FAULTY GEAR SHIFTING........................................................................ 8-2
SHIFT PEDAL DOES NOT MOVE ............................................................ 8-2
JUMPS OUT OF GEAR.............................................................................8-2
FAULTY CLUTCH .....................................................................................8-2
OVERHEATING ........................................................................................8-3
POOR BRAKING PERFORMANCE.......................................................... 8-3
FAULTY FRONT FORK LEGS..................................................................8-3
UNSTABLE HANDLING ............................................................................8-3
FAULTY LIGHTING OR SIGNALING SYSTEM ........................................ 8-4
8
TROUBLESHOOTING
EAS28450
• Sucked-in air
TROUBLESHOOTING
EAS28460
Electrical system
GENERAL INFORMATION 1. Battery
TIP
• Discharged battery
• Faulty battery
The following guide for troubleshooting does not
2. Fuse(s)
cover all the possible causes of trouble. It should
• Blown, damaged or incorrect fuse
be helpful, however, as a guide to basic trouble-
• Improperly installed fuse
shooting. Refer to the relative procedure in this
3. Spark plug(s)
manual for checks, adjustments, and replace-
• Incorrect spark plug gap
ment of parts.
• Incorrect spark plug heat range
• Fouled spark plug
EAS28470
STARTING FAILURES • Worn or damaged electrode

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

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

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

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

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

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

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

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

Turn signal flashes quickly

• Incorrect turn signal bulb
8-4
EAS28740
57. Horn 2 EAS28750
WIRING DIAGRAM 58. Turn signal relay COLOR CODE

XV19SD(C)/XV19CTSD(C) 2013 59. Left handlebar switch B Black
1. AC magneto 60. Clutch switch Br Brown
2. Rectifier/regulator 61. Dimmer switch Ch Chocolate
62. Turn signal switch Dg Dark green
3. Main switch
G Green
4. Joint 63. Horn switch
Gy Gray
5. Headlight fuse 64. Select switch L Blue
6. Backup fuse (odometer and 65. Front right turn signal/position Lg Light green
clock) light O Orange
7. Main fuse 66. Front left turn signal/position P Pink
8. Battery light R Red
9. Ignition fuse 67. Headlight assembly Sb Sky blue
10. ECU fuse 68. Headlight (low beam) W White
11. Signaling system fuse 69. Headlight (high beam) Y Yellow
70. Right handlebar switch B/Br Black/Brown
12. Auxiliary DC connector fuse
B/G Black/Green
13. Auxiliary DC coupler 71. Front brake light switch
B/L Black/Blue
14. Fuel injection system fuse 72. Engine stop switch B/R Black/Red
15. Starter relay 73. Start switch B/W Black/White
16. Starter motor 74. Accessory light switch B/Y Black/Yellow
17. Diode 75. Accessory light (OPTION) Br/L Brown/Blue
18. Headlight relay 76. Rear brake light switch Br/W Brown/White
19. Relay unit 77. Tail/brake light assembly G/B Green/Black
20. Starting circuit cut-off relay 78. Tail/brake light G/L Green/Blue
21. Fuel pump relay 79. License plate light G/W Green/White
22. Neutral switch 80. Rear left turn signal light G/Y Green/Yellow
81. Rear right turn signal light Gy/G Gray/Green
23. Sidestand switch
Gy/R Gray/Red
24. Throttle position sensor Gy/W Gray/White
25. Engine temperature sensor L/B Blue/Black
26. Air temperature sensor L/G Blue/Green
27. Intake air pressure sensor L/R Blue/Red
28. Lean angle sensor L/W Blue/White
29. Speed sensor L/Y Blue/Yellow
30. Crankshaft position sensor P/L Pink/Blue
31. Joint connector P/W Pink/White
32. ECU (engine control unit) R/B Red/Black
R/G Red/Green
33. Cylinder-#1 left ignition coil
R/L Red/Blue
34. Cylinder-#1 right ignition coil R/W Red/White
35. Cylinder-#2 left ignition coil R/Y Red/Yellow
36. Cylinder-#2 right ignition coil Sb/W Sky blue/White
37. Spark plug W/B White/Black
38. ISC (idle speed control) unit W/G White/Green
39. Injector #2 W/R White/Red
40. Injector #1 W/Y White/Yellow
41. EXUP servo motor Y/B Yellow/Black
42. O2 sensor Y/G Yellow/Green
Y/L Yellow/Blue
43. Meter assembly Y/R Yellow/Red
44. Neutral indicator light
45. Multi-function meter
46. Reset switch
47. Engine trouble warning light
48. Fuel level warning light
49. Left turn signal indicator light
50. Right turn signal indicator light
51. Meter light
52. High beam indicator light
53. Fuel pump
54. Fuel sender (fuel pump)
55. Fuel sender (fuel tank)
56. Horn 1
EAS1D77006
57. Front left turn signal/position EAS1D77011
WIRING DIAGRAM light COLOR CODE

XV19CSD(C)/XV19CD(C) 2013 58. Headlight B Black
1. AC magneto 59. Accessory light (OPTION) Br Brown
2. Rectifier/regulator 60. Right handlebar switch Ch Chocolate
61. Front brake light switch Dg Dark green
3. Main switch
G Green
4. Joint 62. Engine stop switch
Gy Gray
5. Main fuse 63. Start switch L Blue
6. Battery 64. Accessory light switch Lg Light green
7. Fuel injection system fuse 65. Rear right turn signal light O Orange
8. Starter relay 66. Rear left turn signal light P Pink
9. Starter motor 67. License plate light R Red
10. Relay unit 68. Tail/brake light Sb Sky blue
11. Starting circuit cut-off relay 69. Rear brake light switch W White
12. Fuel pump relay 70. Backup fuse (odometer and Y Yellow
clock) B/G Black/Green
13. Neutral switch
B/L Black/Blue
14. Joint connector 71. Headlight fuse
B/R Black/Red
15. Fuel sender (fuel pump) 72. ECU fuse B/W Black/White
16. Fuel pump 73. Signaling system fuse B/Y Black/Yellow
17. Engine temperature sensor 74. Ignition fuse Br/L Brown/Blue
18. Throttle position sensor 75. Auxiliary DC connector fuse Br/W Brown/White
19. Air temperature sensor 76. Auxiliary DC coupler Br/Y Brown/Yellow
20. Intake air pressure sensor 77. Sidestand switch G/L Green/Blue
21. Lean angle sensor G/R Green/Red
22. Crankshaft position sensor G/W Green/White
23. Speed sensor G/Y Green/Yellow
Gy/B Gray/Black
Gy/W Gray/White
25. Cylinder-#1 left ignition coil Gy/Y Gray/Yellow
26. Cylinder-#1 right ignition coil L/B Blue/Black
27. Cylinder-#2 left ignition coil L/G Blue/Green
28. Cylinder-#2 right ignition coil L/R Blue/Red
29. Spark plug L/W Blue/White
30. Injector #2 L/Y Blue/Yellow
31. Injector #1 P/W Pink/White
32. O2 sensor R/B Red/Black
R/G Red/Green
R/L Red/Blue
34. ISC (idle speed control) unit R/W Red/White
35. Meter assembly R/Y Red/Yellow
36. Neutral indicator light Sb/W Sky blue/White
37. Multi-function meter W/B White/Black
38. Engine trouble warning light W/G White/Green
39. Fuel level warning light W/R White/Red
40. Reset switch W/Y White/Yellow
41. Meter light Y/B Yellow/Black
42. High beam indicator light Y/G Yellow/Green
Y/L Yellow/Blue
43. Left turn signal indicator light
Y/R Yellow/Red
44. Right turn signal indicator light
45. Fuel sender (fuel tank)
46. Horn 1
47. Horn 2
48. Turn signal relay
49. Headlight relay
50. Left handlebar switch
51. Clutch switch
52. Dimmer switch
53. Turn signal switch
54. Horn switch
55. Select switch
56. Front right turn signal/position
light
XV19SD(C)/XV19CTSD(C) 2013 WIRING DIAGRAM
6
(BLACK) 19
20 21 31 (BLACK)
1 7 4 33
2 4 4 B
(BLACK) 37
(GRAY)
14 34
8 B
23 4 C 37
3 15 WIRE HARNESS SUB-WIRE-HARNESS2
ON
22 (BLACK) (BLACK)
C
35 C
OFF
17 4 37
16
C
36
D 37 WIRE HARNESS SUB-WIRE-HARNESS3
D D
E D 38
24 E 32 D
9 (BLACK) E
4
4 18 B
(BLACK)
25 B D
D
(BLACK) (BLACK)
10
4 26 39
(BLACK) (GRAY) E
B B
11 27
(BLACK) 40 (DARK GRAY)
B B
12 28
29
41
30 (BLACK)
13
4 4 4 4 4
4 42
(BLACK)
4 4
4
76 31 43 44
(BLACK) 57 56 4
(BLACK) (BLACK) 4
58
70 59 45
4 46 (BLACK)
(BLACK)
61 62 63 64
72 73 74 4 (BLUE) (BLUE) (L) PUSH
N (BLACK) (BLACK)
(R)
4 4 55 47
(GRAY) (GRAY)
60 54 53
(BLACK)
71 48
(BLACK)
(GRAY) (GRAY)
49
(GRAY)
(GRAY)
50
77
51
52
78 79 80 81 4 67
75 66 65
68 69 (GRAY) (GRAY) (BLACK) (BLACK)
4 (BLACK) (BLACK)
31
XV19CSD(C)/XV19CD(C) 2013 WIRING DIAGRAM
10
11 12 (BLACK) (BLACK)
(GRAY) (BLACK)
4
5
1 2 4 A
14 4 4 25
15 16
4 29
(GRAY)
13 26 WIRE HARNESS SUB-WIRE-HARNESS1
4 29 B
27
29
17 B
B 28 WIRE HARNESS SUB-WIRE-HARNESS2
3 6 7 (BLACK) C C
ON 18 C 29
OFF
8 (BLACK) C 30 (GRAY)
B B
19 24
(RED) (BLACK)
31 (DARK GRAY)
B B WIRE HARNESS SUB-WIRE-HARNESS2
9 20
(RED) (BLACK)
4 4 21 32
4 (BLACK)
22
4 33
23 (BLACK)
14 14 14 34
(BLACK)
4
70
14
71
72
4
14
4 4 35
(BLACK)
47 46
73 49 36
74 48
4 4
37
75
50
52 53 54 55 38
69 (GREEN) (GREEN)
(L) PUSH
60 N 39 45
(R)
(BLACK) (BLACK)
62 63 64 (BLACK) (BLACK) 40
51
77
(BLACK)
41
76 4 (YELLOW) (YELLOW)
(BLACK) (BLACK)
61 (GRAY)
42
4 43
(BLACK)
(BLACK)
A 44
4 68 A
67
59
66 65 14
(YELLOW) (GRAY) (BLACK) 4 58 4 57 56 4
(GRAY) (BLACK)
(YELLOW) (GRAY) (BLACK)

14 (GRAY) (BLACK)

2013 Yamaha Raider S Stratoliner S Roadliner S Service Manual

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2013 Yamaha Raider S Stratoliner S Roadliner S Service Manual

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2013

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

1. Serviceable with engine mounted

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

IMPORTANT INFORMATION ....................................................................... 1-10

CHECKING THE CONNECTIONS ................................................................1-12

SPECIAL TOOLS .......................................................................................... 1-13

VEHICLE IDENTIFICATION NUMBER

OUTLINE OF THE FI SYSTEM

1. Pressure regulator 13. Intake air pressure sensor

INSTRUMENT FUNCTIONS (for XV19S(C)/

Multi-function meter unit

Tachometer Odometer, tripmeter, fuel reserve tripmeter,

To set the clock

1. Push the “SELECT” switch to change the dis- 2. LCD

1. Fault code display 2

Brightness control mode

1. Multi-function meter unit panel

INSTRUMENT FUNCTIONS (for XV19CS(C)/ 1. “SELECT” switch

Multi-function meter unit 5080

To set the clock

If the odometer/tripmeter/clock display indicates

Brightness control mode

1. Multi-function meter unit panel

To set the brightness

1. Multi-function meter unit panel

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS Pocket tester

Tappet adjusting tool (4 mm) 3-6, 3-7

Oil filter wrench 3-12

Belt tension gauge 3-26

Steering nut wrench 3-27, 4-81

Damper rod holder 4-71, 4-73

T-handle 4-71, 4-73

Fork seal driver 4-73, 4-74

Pivot shaft wrench 5-15

Valve spring compressor 5-42, 5-47

Valve guide installer (ø6) 5-43

Valve guide reamer (ø6) 5-43

Piston pin puller set 5-49

Universal clutch holder 5-64, 5-70

Sheave holder 5-64, 5-69,

Rotor puller 5-80

Vacuum/pressure pump gauge set 6-15

Pressure gauge 6-15

Fuel pressure adapter 6-15

Digital circuit tester 6-15

Ignition checker 7-84

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

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

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

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

TIGHTENING TORQUES .............................................................................. 2-19

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-32

LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-35

CABLE ROUTING (for XV19S(C)/ XV19CTS(C)).........................................2-49