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XV19SW
Yamaha XV19SW User Manual
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Y
amaha Service Manual
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2
Table of Contents
Table of Contents
8
How to Use this Manual
5
Symbols
6
General Information
10
Identification
11
Vehicle Identification Number
11
Model Label
11
Features
12
Outline of the Fi System
12
Fi System
13
Instrument Functions
14
Important Information
18
Preparation for Removal and Disassembly
18
Replacement Parts
18
Gaskets, Oil Seals and O-Rings
18
Lock Washers/Plates and Cotter Pins
18
Bearings and Oil Seals
19
Circlips
19
Checking the Connections
20
Special Tools
21
Specifications
26
General Specifications
27
Engine Specifications
28
Chassis Specifications
36
Electrical Specifications
39
Tightening Torques
42
General Tightening Torque Specifications
42
Engine Tightening Torques
43
Chassis Tightening Torques
48
Lubrication Points and Lubricant Types
53
Engine
53
Chassis
55
Lubrication System Chart and Diagrams
57
Engine Oil Lubrication Chart
57
Lubrication Diagrams
59
Cable Routing
71
Periodic Checks and Adjustments
88
Periodic Maintenance
91
General Maintenance and Lubrication Chart
91
Introduction
91
Periodic Maintenance Chart for the Emission Control System
91
Engine
94
Adjusting the Valve Clearance
94
Synchronizing the Throttle Bodies
97
Adjusting the Throttle Cable Free Play
98
Checking the Spark Plugs
99
Checking the Ignition Timing
100
Checking the Engine Oil Level
101
Changing the Engine Oil
101
Checking the Transfer Gear Oil Level
103
Changing the Transfer Gear Oil
104
Checking the Clutch Fluid Level
104
Bleeding the Hydraulic Clutch System
105
Replacing the Air Filter Element
105
Checking the Throttle Body Joints
106
Checking the Fuel Line
106
Checking the Cylinder Head Breather Hose
107
Checking the Oil Tank Breather Hose
107
Checking the Exhaust System
107
CHECKING the CANISTER (for California Only)
108
Adjusting the Exup Cables
108
Chassis
110
Adjusting the Rear Disc Brake
110
Checking the Brake Fluid Level
110
Checking the Front Brake Pads
111
Checking the Rear Brake Pads
111
Checking the Front Brake Hoses
111
Checking the Rear Brake Hoses
112
Adjusting the Rear Brake Light Switch
112
Bleeding the Hydraulic Brake System
112
Adjusting the Shift Pedal
113
Adjusting the Drive Belt Slack
114
Checking and Adjusting the Steering Head
115
Checking the Front Fork
116
Adjusting the Rear Shock Absorber Assembly
117
Checking the Tires
117
Checking the Wheels
119
Checking and Lubricating the Cables
119
Lubricating the Levers
120
Lubricating the Pedal
120
Lubricating the Sidestand
120
Lubricating the Rear Suspension
120
Electrical System
121
Chassis
124
General Chassis
127
Removing the Windshield
128
Assembling the Windshield
128
Installing the Windshield
128
Removing the Backrest
131
Assembling the Backrest
131
Installing the Backrest
131
Checking the Sidebag Bracket Spring Nuts
134
Front Wheel
141
Removing the Front Wheel
144
Disassembling the Front Wheel
144
Checking the Front Wheel
144
Assembling the Front Wheel
145
Adjusting the Front Wheel Static Balance
145
Installing the Front Wheel (Front Brake Discs)
146
Rear Wheel
149
Removing the Rear Wheel (Disc)
154
Disassembling the Rear Wheel
154
Checking the Rear Wheel
154
Checking the Rear Brake Caliper Bracket
154
Checking the Rear Wheel Drive Hub
155
Checking and Replacing the Rear Wheel Pulley
155
Assembling the Rear Wheel
155
Adjusting the Rear Wheel Static Balance
155
Installing the Rear Wheel (Disc)
155
Front Brake
157
Introduction
162
Checking the Front Brake Discs
162
Replacing the Front Brake Pads
163
Removing the Front Brake Calipers
164
Disassembling the Front Brake Calipers
164
Checking the Front Brake Calipers
165
Assembling the Front Brake Calipers
165
Installing the Front Brake Calipers
165
Removing the Front Brake Master Cylinder
166
Checking the Front Brake Master Cylinder
166
Assembling the Front Brake Master Cylinder
167
Installing the Front Brake Master Cylinder
167
Rear Brake
169
Introduction
175
Checking the Rear Brake Disc
175
Replacing the Rear Brake Pads
175
Removing the Rear Brake Caliper
176
Disassembling the Rear Brake Caliper
176
Checking the Rear Brake Caliper
177
Assembling the Rear Brake Caliper
177
Installing the Rear Brake Caliper
177
Removing the Rear Brake Master Cylinder
178
Checking the Rear Brake Master Cylinder
178
Assembling the Rear Brake Master Cylinder
179
Installing the Rear Brake Master Cylinder
179
Handlebar
181
Removing the Handlebar
183
Checking the Handlebar
183
Installing the Handlebar
183
Front Fork
186
Removing the Front Fork Legs
190
Disassembling the Front Fork Legs
190
Checking the Front Fork Legs
191
Assembling the Front Fork Legs
191
Installing the Front Fork Legs
194
Steering Head
195
Removing the Lower Bracket
197
Checking the Steering Head
197
Installing the Steering Head
197
Rear Shock Absorber Assembly and Swingarm
199
Handling the Rear Shock Absorber
202
Disposing of a Rear Shock Absorber
202
Removing the Rear Shock Absorber Assembly and Swingarm
202
Checking the Rear Shock Absorber Assembly
203
Checking the Connecting Arm and Relay Arm
203
Checking the Swingarm
203
Installing the Relay Arm, Rear Shock Absorber Assembly and Connecting Arms
203
Installing the Swingarm
205
Belt Drive
206
Removing the Drive Belt and Drive Pulley
206
Checking the Drive Belt
208
Installing the Drive Belt and Drive Pulley
208
Engine
210
Engine Removal
213
Installing the Shift Pedal Assembly
217
Checking the Oil Cooler
219
Removing the Engine
224
Installing the Engine
224
Camshafts
226
Removing the Cylinder Head Covers
233
Removing the Rocker Arms, Push Rods and Valve Lifters
233
Removing the Camshafts
233
Checking the Camshafts
235
Checking the Rocker Arms and Rocker Arm Shafts
236
Checking the Rocker Arm Bases
237
Checking the Push Rods
237
Checking the Valve Lifters and Valve Lifter Cases
237
Checking the Push Rod Cover
238
Checking the Decompression System
238
Checking the Decompression Cam Spring
238
Checking the Oil Delivery Pipe
239
Installing the Camshafts
239
Bleeding a Valve Lifter
241
Installing the Valve Lifters
242
Installing the Rocker Arms and Push Rods
243
Installing the Cylinder Head Covers
244
Installing the Shift Pedal Assembly
244
Cylinder Heads
245
Removing the Cylinder Heads
247
Checking the Cylinder Heads
247
Checking the Oil Pipe
247
Installing the Cylinder Heads
248
Valves and Valve Springs
251
Removing the Valves
251
Checking the Valves and Valve Guides
251
Checking the Valve Seats
253
Checking the Valve Springs
254
Installing the Valves
255
Cylinders and Pistons
258
Removing the Piston
258
Checking the Cylinders and Pistons
258
Checking the Piston Rings
259
Checking the Piston Pins
260
Installing the Pistons and Cylinders
260
Clutch
262
Removing the Clutch
272
Removing the Primary Drive Gear
272
Removing the Left Balancer Drive Gear
272
Checking the Friction Plates
273
Checking the Clutch Plates
273
Checking the Clutch Spring Plate
273
Checking the Clutch Housing
274
Checking the Clutch Boss
274
Checking the Pressure Plate
274
Checking the Clutch Push Rods
274
Checking the Primary Drive Gear
274
Checking the Primary Driven Gear
274
Checking the Left Balancer Gears
274
Installing the Left Balancer Drive Gear
275
Installing the Primary Drive Gear
276
Installing the Clutch
277
Disassembling the Clutch Master Cylinder
278
Checking the Clutch Master Cylinder
278
Assembling the Clutch Master Cylinder
279
Installing the Clutch Master Cylinder
279
Removing the Clutch Release Cylinder
280
Checking the Clutch Release Cylinder
280
Assembling the Clutch Release Cylinder
280
Installing the Clutch Release Cylinder
281
Shift Shaft
283
Checking the Shift Shaft
283
Checking the Stopper Lever
283
Installing the Shift Shaft
283
Generator and Starter Clutch
284
Removing the Generator
286
Removing the Starter Clutch
286
Checking the Starter Clutch
286
Checking the Torque Limiter
287
Installing the Starter Clutch
287
Installing the Generator
287
Electric Starter
289
Checking the Starter Motor
291
Assembling the Starter Motor
292
Transfer Gear Case
293
Removing the Middle Driven Shaft
298
Checking the Middle Drive
298
Checking the Oil Strainer
298
Checking the Transfer Gear Oil Pump
298
Checking the Oil Pipes
299
Assembling the Transfer Gear Oil Pump
299
Installing the Transfer Gear Case
299
Crankcase
301
Disassembling the Crankcase
304
Checking the Crankcase
304
Checking the Bearings and Oil Seal
304
Checking the Oil Delivery Pipe and Oil Pipe
304
Checking the Oil Strainers
304
Checking the Engine Oil Pump Driven Gear
305
Installing the Bearing Retainers
305
Assembling the Crankcase
305
Oil Pump
307
Checking the Oil Pump
310
Checking the Relief Valve
310
Checking the Ball Spring and Relief Valve Spring
310
Checking the Oil Strainer
311
Assembling the Oil Pump
311
Installing the Oil Pump
312
Crankshaft
313
Removing the Connecting Rods
314
Checking the Crankshaft and Connecting Rods
314
Installing the Connecting Rods
317
Installing the Crankshaft Assembly
318
Transmission
319
Checking the Shift Forks
323
Checking the Shift Drum Assembly
323
Checking the Transmission
323
Assembling the Main Axle and Drive Axle
324
Installing the Shift Forks and Shift Drum Assembly
324
Fuel System
326
Default Chapter
327
Fuel Tank
327
Fuel Tank
329
Removing the Fuel Tank
329
Removing the Fuel Pump
329
Checking the Fuel Pump Body
330
Checking the Fuel Pump Operation
330
Installing the Fuel Pump
330
Installing the Fuel Tank
330
Throttle Bodies
336
Removing the Fuel Hose
337
Checking the Injectors
337
Checking the Throttle Bodies
337
Checking the Rollover Valves
337
Checking the Pressure Regulator
337
Checking the Pressure Regulator Operation
337
Installing the Fuel Pipe
338
Installing the Fuel Hose
339
Isc (Idle Speed Control) Unit
340
Checking the Isc (Idle Speed Control) System
341
Electrical System
342
Ignition System
345
Circuit Diagram
345
Engine Stopping Due to Sidestand Operation
347
Troubleshooting
348
Electric Starting System
351
Circuit Diagram
351
Starting Circuit Cut-Off System Operation
353
Troubleshooting
355
Charging System
357
Circuit Diagram
357
Troubleshooting
359
Lighting System
361
Circuit Diagram
361
Troubleshooting
363
Signaling System
365
Circuit Diagram
365
Troubleshooting
367
Fuel Injection System
371
Circuit Diagram
371
Ecu Self-Diagnostic Function
373
Self-Diagnostic Function Table
374
Troubleshooting Method
376
Diagnostic Mode
377
Troubleshooting Details
384
Fuel Pump System
407
Circuit Diagram
407
Troubleshooting
409
Electrical Components
411
Checking the Switches
415
Checking the Bulbs and Bulb Sockets
418
Checking the Fuses
419
Checking and Charging the Battery
420
Checking the Relays
423
Checking the Turn Signal Relay
424
Checking the Diodes
425
Checking the Ignition Spark Gap
426
Checking the Spark Plug Caps
427
Checking the Ignition Coils
427
Checking the Crankshaft Position Sensor
428
Checking the Lean Angle Sensor
428
Checking the Starter Motor Operation
429
Checking the Stator Coil
429
Checking the Rectifier/Regulator
429
Checking the Horns
430
Checking the Engine Temperature Sensor
431
Checking the Fuel Sender (Fuel Tank)
431
Checking the Fuel Sender (Fuel Pump)
432
Checking the Fuel Level Warning Light
432
Checking the Speed Sensor
432
Checking the Throttle Position Sensor
433
Checking the Fuel Pump
433
Checking the Exup Servo Motor
434
Checking the Intake Air Pressure Sensor
434
Checking the Air Temperature Sensor
434
Troubleshooting
436
General Information
437
Incorrect Engine Idling Speed
437
Starting Failures
437
Troubleshooting
437
Faulty Clutch
438
Faulty Gear Shifting
438
Jumps out of Gear
438
Poor Medium and High-Speed Performance
438
Shift Pedal Does Not Move
438
Faulty Front Fork Legs
439
Overheating
439
Poor Braking Performance
439
Unstable Handling
439
Faulty Lighting or Signaling System
440
Wiring Diagram
442
4
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Yamaha XV19SW Specifications
General
Brand
Yamaha
Model
XV19SW
Category
Motorcycle
Language
English
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