Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 4

 

  Index      Manuals     Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual

 

Search            copyright infringement  

 

 

 

 

 

 

 

 

Content      ..     2      3      4      5     ..

 

 

Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 4

 

 

TIGHTENING TORQUES

2-26

* For XV19CTS(C), XV19CT(C) and XV19CTM(C)

NOTE:

1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m·kg, 37 ft·lb) with a torque wrench, then 

loosen the lower ring nut completely.

2. Retighten the lower ring nut to 18 Nm (1.8 m·kg, 13 ft·lb) with a torque wrench.

Drive pulley cover bolt

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Rectifier/regulator cover bolt

M6

6

10 Nm (1.0 m·kg, 7.2 ft·lb)

Lead cover bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Rectifier/regulator bolt

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Drive pulley cover plate bolt

M6

3

5 Nm (0.5 m·kg, 3.6 ft·lb)

Wire harness guide bolt

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Throttle cable guide bolt (upper 
side)

M6

1

7 Nm (0.7 m·kg, 5.1 ft·lb)

Throttle cable guide bolt (lower 
side)

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Rear shock absorber locknut

M50

1

30 Nm (3.0 m·kg, 22 ft·lb)

Windshield holder bracket as-
sembly bolt*

M8

4

30 Nm (3.0 m·kg, 22 ft·lb)

Windshield holder nut*

M8

4

23 Nm (2.3 m·kg, 17 ft·lb)

Windshield bracket brace nut*

M6

4

10 Nm (1.0 m·kg, 7.2 ft·lb)

Windshield brace nut*

M6

6

10 Nm (1.0 m·kg, 7.2 ft·lb)

Windshield lock nut*

M24

1

12 Nm (1.2 m·kg, 8.7 ft·lb)

Windshield lock cover nut*

M6

1

8 Nm (0.8 m·kg, 5.8 ft·lb)

Backrest upper bracket and back-
rest lower bracket bolt*

M8

4

23 Nm (2.3 m·kg, 17 ft·lb)

Backrest pad and backrest up-
per bracket bolt*

M6

1

10 Nm (1.0 m·kg, 7.2 ft·lb)

Backrest pad and backrest up-
per bracket stay bolt*

M6

2

10 Nm (1.0 m·kg, 7.2 ft·lb)

Backrest lock nut*

M24

1

12 Nm (1.2 m·kg, 8.7 ft·lb)

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

M10

4

47 Nm (4.7 m·kg, 34 ft·lb)

Sidebag bracket bolt*

M8

4

23 Nm (2.3 m·kg, 17 ft·lb)

Sidebag bracket brace nut*

M8

2

23 Nm (2.3 m·kg, 17 ft·lb)

Item

Thread 

size

Q’ty

Tightening torque

Remarks

LT

LT

LT

LT

LT

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION POINTS AND LUBRICANT TYPES

2-27

EAS20360

LUBRICATION POINTS AND LUBRICANT TYPES

EAS20370

ENGINE

Lubrication point

Lubricant

Oil seal lips

O-rings

Bearings

Cylinder head nuts and washers

Connecting rod small end and big end

Crankshaft journals

Piston surfaces

Piston pins

Connecting rod bolts

Balancer idle gear inner surface and balancer idle gear shaft

Left balancer driven gear inner surface

Right balancer

Gasket (left balancer driven gear housing)

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

Camshaft cam lobes and camshaft journals

Flange bolt (camshaft gear) 

Valve push rod end balls

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Valve lifters

Rocker arms

Rocker arm shafts

Camshaft (front and rear cylinders)

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

Oil pump driven gear shaft

Crankcase stud bolt ends

Starter clutch idle gear shaft

Starter clutch idle gear inner surface

Starter clutch gear inner surface and outer surface

Generator shaft journal

LS

LS

E

E

E

M

E

E

M

E

M

M

LS

E

M

E

E

M

E

E

E

E

E

LS

E

E

E

E

E

E

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION POINTS AND LUBRICANT TYPES

2-28

Primary driven gear inner surface

Clutch push rods and ball

Clutch boss nut and washer

Transmission gears (wheel and pinion) and collar

Drive pulley nut and washer

Shift forks and shift fork guide bars

Shift drum

Shift shaft and shift shaft oil seal

Shift fork pawl

Crankcase mating surface

Yamaha bond 

No.1215 (Three Bond 

No.1215

®

)

Stator coil lead grommet

Yamaha bond 

No.1215 (Three Bond 

No.1215

®

)

Crankshaft position sensor lead grommet

Yamaha bond 

No.1215 (Three Bond 

No.1215

®

)

Lubrication point

Lubricant

E

LS

E

M

E

E

E

LS

M

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION POINTS AND LUBRICANT TYPES

2-29

EAS20380

CHASSIS

Lubrication point

Lubricant

Steering bearings and upper bearing dust cover lip

Lower bearing dust seal lip

Front wheel oil seal lips (left and right)

Rear wheel oil seal lips

Rear wheel drive hub oil seal lip

Rear wheel drive hub mating surface

Tube guide (throttle grip) inner surface and throttle cables

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

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

Brake pedal shaft pivoting point

Shift pedal pivoting point

Passenger footrest pivoting point and ball

Sidestand pivoting point and metal-to-metal moving parts

Dowel pins (rear fender stay)

Pivot shaft

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

Rear shock absorber bushings and O-rings

Swingarm, relay arm bearings, and oil seal lips

Connecting arm bushings and O-rings

Rear wheel axle

Clutch master cylinder push rod pin and contact surface

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

LS

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION POINTS AND LUBRICANT TYPES

2-30

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-31

EAS20390

LUBRICATION SYSTEM CHART AND DIAGRAMS

EAS20400

ENGINE OIL LUBRICATION CHART

22

21

19

18

20

23

17

16

15

11

10

14

13

9

8

12

14

7

6

5

4

2

3

1

9

8

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-32

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

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-33

EAS20410

LUBRICATION DIAGRAMS

E

A-A

B-B

E-E

D-D

C

C

A

A

B

E

D

D

B

2

9

3

8

1

10

4

5

6

7

8

11

4

5

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-34

1. Oil tank
2. Dipstick
3. Oil pipe 2
4. Oil delivery pipe 1
5. Oil filter cartridge
6. Oil delivery pipe 2
7. Oil pipe 3
8. Oil pipe 4
9. Oil pipe 5
10. Oil strainer (oil tank)
11. Oil delivery pipe 3

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-35

D

D

B-B

D-D

C-C

A

A

B

C

C

B

3

2

1

3

4

6

7

6

7

5

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-36

1. Valve lifter
2. Push rod
3. Rocker arm shaft
4. Oil pipe 1
5. Crankshaft
6. Oil pipe (“F” mark)
7. Oil pipe (“R” mark)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-37

A-A

A

A

1

3

2

4

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-38

1. Oil pipe 1
2. Oil pump
3. Oil strainer (crankcase)
4. Joint pipe

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-39

A

1

2

3

4

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-40

1. Main axle
2. Drive axle
3. Oil strainer (crankcase)
4. Oil pump
A. To the oil filter cartridge

-------------------------------------------------------------------------------------------------------------------------------------------------------------

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-41

A

A

A

1

5

5

1

3

2

4

B

B

B-B

-------------------------------------------------------------------------------------------------------------------------------------------------------------

 

 

 

 

 

 

 

Content      ..     2      3      4      5     ..