Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 5

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-42

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

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-43

1

2

LUBRICATION SYSTEM CHART AND DIAGRAMS

2-44

1. Transfer gear oil pump
2. Middle driven shaft

CABLE ROUTING

2-45

EAS20430

CABLE ROUTING

C

D

F

F

C

D

B-B

C-C

D-D

F-F

A

E

A

E

B

B

1

1

1

1

2

3

4

5

5

5

5

5

6

6

6

6

7

7

7

7

8

9

10

11

A

B

C

E

F

G

D

CABLE ROUTING

2-46

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. 10

–

30

°

E. Fasten the rear brake light switch lead with the 

plastic locking tie. Face the end of the plastic 
locking tie inward, and then cut off the excess end 
of the tie.

F. Make sure that there is no slack in the rear brake 

light switch lead in the area shown in the illustration.

G. Fasten the rear brake light switch lead with the 

plastic locking tie. Face the end of the plastic 
locking tie downward, and then cut off the excess 
end of the tie.

CABLE ROUTING

2-47

B

B

C

D

D

E

E

B-B

G-G

F-F

E-E

D-D

A

A

C

F

F

1

1

1

1

2

2

2

2

2

3

3

4

4

5

6

6

7

8

8

9

12

G

G

3

B

G

J

H

I

A

C

D

E

F

K

L

10

11

CABLE ROUTING

2-48

1. Main switch lead
2. Right handlebar switch lead
3. Wire harness
4. Left handlebar switch lead
5. Air temperature sensor lead
6. Front left turn signal/position light lead
7. Headlight lead
8. Front right turn signal/position light lead
9. Headlight coupler (high beam)
10. Headlight coupler (low beam)
11. Air temperature sensor
12. Main switch
A. View with headlight lens unit removed.
B. Place the joint coupler behind the leads.
C. Place the sections of the handlebar switch leads 

that are not covered by their protective sleeves in 
the rear of the headlight housing.

D. Fasten the headlight leads, front turn 

signal/position light leads, and accessory light lead 
with the holders along the side of the headlight 
housing.

E. Place the headlight leads, front turn signal/position 

light leads, and accessory light lead near the base 
of the holder.

F. 30 mm (1.18 in)
G. View from rear of headlight lens unit
H. Less than 20 mm (0.79 in). Fasten the headlight 

lead (low beam) with the holder, making sure to 
fasten the protective sleeve of the lead, not the lead 
itself.

I.

Route the headlight lead (high beam) between the 

headlight coupler (low beam) and the stay.

J. Route the headlight lead (high beam) behind the 

headlight lead (low beam).

K. Secure the plastic band by inserting the projection 

on the band into the hole in the headlight housing.

L. Face the end of the plastic band downward.

CABLE ROUTING

2-49

D

D

E

A

A

C

C

C

A-A

J-J

G

G

K

E

B

B

I

F

F

A B

C D

E

F

G

H

I

J

K

L

M

S

1

2

3

3

4

5

6

7

8

9

10

11

12

13

14

14

14

14

14

15

16

17

21

26

F-F

G-G

D-D

H-H

H

H

K

I

B-B

C-C

Z

3

3

20

23

24

25

S

W

V

T

T

T

AH

18

19

27

AE

AD

AF

U

AB

AA

AC

28

Y

X

22

N

P

O

J

J

3

4

T

4

4

O

Q

R

R

R

R

U

V

Y

Z

AG

CABLE ROUTING

2-50

1. EXUP servo motor
2. Fuse box
3. Wire harness
4. Fuel outlet hose
5. Cylinder-#1 right spark plug cap
6. Cylinder-#1 right ignition coil
7. Cylinder-#2 intake air pressure sensor coupler
8. Fuel sender (fuel tank) coupler
9. Meter assembly coupler
10. Throttle cable
11. Front brake hose
12. Cylinder-#2 right spark plug cap
13. Cylinder-#1 left ignition coil
14. Clutch pipe
15. Neutral switch lead
16. Stator coil lead
17. Speed sensor lead
18. O

2

 sensor lead

19. EXUP cable
20. Cylinder-#1 right spark plug lead
21. Cylinder-#1 left spark plug lead
22. ISC (idle speed control) unit inlet hose
23. Cylinder-#2 ISC (idle speed control) unit outlet 

hose

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

hose

25. Sub-wire harness 3 coupler
26. Cylinder-#2 right spark plug lead
27. Sub-wire harness 4 coupler
28. Cylinder-#2 left spark plug lead
A. Fasten the cylinder-#1 left and right spark plug 

leads, fuel outlet hose, wire harness and the fuel 
tank damper with the plastic locking tie. Install the 
plastic locking tie in the rear slot of the fuel tank 
damper.

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

tank damper with the plastic locking tie. Install the 
plastic locking tie in the front slot of the fuel tank 
damper and make sure that the end of the damper 
is aligned with the edge of the flat section on the 
outside of the frame.

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

leads, engine temperature sensor lead, and throttle 
position sensor lead to the guide on the engine 
bracket (right upper side) with the plastic locking tie. 
Face the end of the plastic locking tie rearward, and 
then cut off the excess end of the tie.

D. Fasten sub-wire harness 2 with the plastic locking 

tie.

E. Align the positioning tape on the wire harness with 

the top of the frame.

F. 0

–

15 mm (0

–

0.59 in)

G. Route the throttle cables behind the front brake 

hose.

H. Make sure that the wire harness is not twisted 

between the fuel tank and the headlight assembly.

I.

Position the cylinder-#2 left and right spark plug 

leads, sub-wire harness 2 coupler and sub-wire 
harness 4 coupler on top of the guide.

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

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

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

ties. Face the end of each plastic locking tie 
outward, and then cut off the excess end of the tie.

P. To the rear brake caliper
Q. Install the O

2

 sensor coupler completely onto the 

O

2

 sensor bracket.

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

inside of the frame. Face the end of the plastic 
locking tie upward, and then cut off the excess end 
of the tie.

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

inside of the frame.

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

sub-wire harness 4 coupler between the cylinder-
#2 right spark plug lead and the cylinder-#1 ISC 
unit outlet hose.

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

45

°

 downward.

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

the sub-wire harness 4.

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

cylinder-#2 ISC unit outlet hose.

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

cylinder, making sure that the pipe contacts the 
projection on the cylinder.

AG.To the O

2

 sensor

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

with the projection on the clutch release cylinder.

CABLE ROUTING

2-51

E

D

D

D

D

A

A

C

B

B

C

A-A

B-B

C-C

D-D

E

G-G

F

H

H

F

A B

C

D

E

F

G

H

I

J

K

L

M

N

N

O

Q

R

U

S

T

O

Q

R

S

V

Y

Z

1

1

2 3 4

5

6

7

8

9

10

11

12

13

14

15

16

15

16

17

18

15

16

18

34

18

35

19

20

21

22

23

24

24

25

26

27

28

29

30

31

32

33

36

G

G

X

W

P

AD

AC

AB

AA

AA

1

2

3

CABLE ROUTING

2-52

1. Clutch hose
2. Throttle cable (decelerator cable)
3. Throttle cable (accelerator cable)
4. Cylinder-#2 left spark plug cap
5. Cylinder-#1 left spark plug cap
6. Sub-wire harness 1
7. Rectifier/regulator
8. Crankshaft position sensor lead
9. Stator coil lead
10. Rectifier/regulator lead
11. Lean angle sensor
12. Horn 2 lead
13. Horn 2
14. Sidestand switch
15. Horn 1 lead
16. Rear brake light switch lead
17. Horn 1
18. Starter motor lead
19. Clutch pipe
20. Fuel tank breather/overflow hose
21. Rollover valve
22. Front brake hose
23. Headlight assembly
24. Front fork
25. Frame
26. Main fuse
27. Diode 1
28. Relay unit
29. Turn signal relay
30. Headlight relay
31. Starter relay
32. EXUP servo motor
33. EXUP cable
34. Speed sensor lead
35. Wire harness
36. Canister
A. Route the throttle cables to the inside of the clutch 

hose.

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

the guide.

C. 30

–

40 mm (1.18

–

1.57 in)

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

inside of the frame.

E. Fasten the crankshaft position sensor lead, neutral 

switch lead, and sidestand switch lead with the 
holders.

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

and wire harness with the holders.

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

frame.

H. To the tail/brake light
I.

Fasten the starter motor lead, horn 1 lead, rear 

brake light switch lead, sidestand switch lead, and 
crankshaft position sensor lead with the plastic 
locking tie.

J. Make sure that there is no slack in the stator coil 

lead and rectifier/regulator lead in the area shown 
in the illustration.

K. Fasten the stator coil lead and rectifier/regulator 

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

L. Fasten the lean angle sensor lead, starter motor 

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

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

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

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

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

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

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

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

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

Q. Align the positioning tape on the starter motor lead 

with the engine mounting bolt (front lower side).

R. Pass the fuel tank breather/overflow hose through 

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

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

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

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

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

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

motor lead.

V. Pass the throttle cables through the cable guides 

as shown in the illustration.

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

stator coil lead and rectifier/regulator lead.

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

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

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

plastic locking tie.

Z. Fasten the stator coil lead with the plastic locking 

ties.

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

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

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

box/starter relay bracket.

AC.For California only
AD.Route the horn 1 lead to the rear of the canister.

CABLE ROUTING

2-53

CABLE ROUTING

2-54

1. Meter assembly coupler
2. Cylinder-#2 intake air pressure sensor coupler
3. Cylinder-#1 right spark plug cap
4. Wire harness
5. Negative battery lead
6. EXUP servo motor
7. Fuse box
8. Starter motor lead
9. Positive battery lead
10. Sub-wire harness 1
11. ECU (electronic control unit)
12. Cylinder-#1 left spark plug cap
13. Cylinder-#1 intake air pressure sensor coupler
14. Fuel sender (fuel tank) coupler
15. Neutral switch lead
16. Sidestand switch lead
17. Crankshaft position sensor lead
18. Speed sensor lead
19. Fuel hose (fuel tank to fuel hose joint)
20. Fuel return hose (fuel return pipe to sub-fuel tank)
21. Air vent hose (fuel pump to fuel hose joint)
22. Fuel outlet hose
23. Frame
24. Oil tank
25. Sub-fuel tank
26. Battery
27. Main fuse
28. Fuel pump lead
A. Do not pinch the leads between the fuel tank 

bracket and the frame when installing the bracket.

B. Pass the plastic locking ties through the holes in 

the frame damper, and then fasten the wire harness 
and damper with the ties. Face the end of each 
plastic locking tie upward, and then cut off the 
excess end of the tie.

C. Align the white tape on the wire harness with the 

frame cross member.

D. 20 mm (0.79 in)
E. Fasten the wire harness with the plastic locking tie. 

Face the end of the plastic locking tie upward, and 
then cut off the excess end of the tie.

F. Route the wire harness along the frame.
G. Fasten the wire harness with the plastic locking tie, 

making sure to align the tie with the line on the 
rubber damper. Face the end of the plastic locking 
tie upward, and then cut off the excess end of the 
tie.

H. Connect the ECU couplers, and then fasten the 

ECU with the band.

I.

Fasten the fuel return hose (fuel return pipe to sub-

fuel tank) with the plastic locking tie. Face the end 
of the plastic locking tie inward, and then cut off the 
excess end of the tie.

J. Route the cylinder-#1 intake air pressure sensor 

lead so that it does not protrude past the top of the 
frame.

K. Fasten the fuel tank damper with the plastic locking 

tie. Install the plastic locking tie in the middle slot of 
the fuel tank damper.

L. Fasten the air filter case damper with the plastic 

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

M. Route the crankshaft position sensor lead, 

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

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

motor lead and battery positive lead.

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

relay) over the tray.

S. Route the negative battery lead towards the front of 

the vehicle.

T. Route the positive battery lead (battery to starter 

relay) under the tray.

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

(crankshaft position sensor coupler, auxiliary DC 
jack coupler, neutral switch coupler, sub-wire 
harness 1 coupler, speed sensor coupler, and 
sidestand switch coupler) and the wire harness.

Y. When installing the ECU, be sure not to pinch the 

leads in the areas shown in the illustration with 
oblique lines.

CABLE ROUTING

2-55

C-C

B

C

C

A

A

B

D

E

C

L

N

1

2

3

4

4

5

5

6

6

7

7

4

5

6

7

8

8

8

9

10

11

11

11

12

14

13

15

16

17

18

19

20

21

22

26

27

A

B

F

G

H

I

J

K

L

M

O

P

Q

R

S

T

U

V

W

X

21

23

24

25

28

H

F

24

G

CABLE ROUTING

2-56

1. Fuel tank breather hose
2. Fuel sender (fuel tank)
3. Fuel tank
4. Fuel hose (fuel tank to fuel hose joint)
5. Fuel return hose (fuel return pipe to sub-fuel tank)
6. Air vent hose (fuel hose joint to fuel tank)
7. Fuel hose joint
8. Fuel outlet hose
9. Fuel pump
10. Sub-fuel tank
11. Fuel hose (fuel hose joint to fuel pump)
12. Fuel return pipe
13. Fuel return hose (pressure regulator to fuel return 

pipe)

14. Pressure regulator
15. Rollover valve 1
16. Rollover valve 2
17. Cylinder-#2 left spark plug lead
18. Rollover valve hose 1
19. Rollover valve hose 2
20. Starter motor lead
21. Fuel tank breather/overflow hose
22. Rollover valve hose 4
23. Rollover valve hose 3
24. Air vent hose (fuel pump to fuel hose joint)
25. Fuel pump coupler
26. Canister purge hose (for California only)
27. Canister (for California only)
28. Canister breather hose (for California only)
A. Align the blue paint mark on the fuel hose (fuel 

hose joint to fuel tank) with the round indentation on 
the bend in the fuel hose joint.

B. Face the fastener of the clamp downward, making 

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

C. Align the white paint mark on the end of the fuel 

return hose (fuel return pipe to sub-fuel tank) with 
the white paint mark on the fuel return pipe.

D. White paint mark
E. Align the ends of the hose clamp with the white 

paint mark on the fuel return hose.

F. Align the paint marks on the hoses with the hose 

joint as shown in the illustration.

G. Fasten the fuel tank breather/overflow hose to the 

throttle cable guide with the holder.

H. Align the paint mark on the hose with the hose joint 

as shown in the illustration.

I.

Fasten the fuel tank breather/overflow hose and 

starter motor lead with the holder.

J. To the fuel injector
K. Align the yellow paint mark on the air vent hose 

(fuel hose joint to fuel tank) with the round 
indentation on the bend in the fuel hose joint.

L. Face the fastener of the clamp to the left.
M. Face the ends of the hose clamp forward.
N. Install the air vent hose (fuel pump to fuel hose 

joint) with its white paint mark facing upward.

O. Face the ends of the hose clamp upward.
P. Face the fastener of the clamp upward, making 

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

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

with its white paint mark facing downward.

R. To the pressure regulator
S. Install the air vent hose (fuel hose joint to fuel tank) 

with its white paint mark facing downward.

T. For California only
U. To the fuel tank
V. To the intake manifold assembly
W. Fasten the canister purge hose and fuel tank 

breather/overflow hose with the holder, making sure 
to align the paint mark on the breather/overflow 
hose with the holder.

X. Fasten the canister purge hose and throttle cable 

guide with the holder.

CABLE ROUTING

2-57

C-C

B

A

B

A

C

C

A

B

D

C

E

F

H

G

I

J

1

2

3

4

5

4

5

6

7

8

9

10

11

12

13

11

13

14

15

16

17

18

19

20

22

7

11

11

13

13

11

21

K