Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 6

CABLE ROUTING

2-58

1. Cylinder-#1 intake air pressure sensor
2. Cylinder-#1 intake air pressure sensor hose
3. Air filter case breather hose 1
4. Fuel hose (intake manifold assembly to pressure 

regulator)

5. Pressure regulator
6. Air filter case breather hose 2
7. Canister purge hose (for California only)
8. ISC (idle speed control) unit inlet hose
9. Canister (for California only)
10. Fuel tank breather/overflow hose (for California 

only)

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

hose

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

hose

14. Cylinder-#2 intake air pressure sensor
15. Cylinder-#1 intake air pressure sensor hose
16. Fuel outlet hose
17. Cylinder head breather hose
18. Hose joint cover
19. Throttle position sensor
20. Cylinder-#1 injector coupler
21. Engine temperature sensor coupler
22. Sub-wire harness 2
A. Face the ends of the hose clamp to the left, angled 

45

°

 rearward.

B. Install the cylinder-#1 intake air pressure sensor 

hose onto the throttle body pipe up to the bend in 
the pipe, making sure to face the white paint mark 
on the hose upward. Face the ends of the hose 
clamp forward.

C. Fasten the canister purge hose and the air filter 

case breather hose 2 with the hose clamp, making 
sure to face the ends of the clamp upward (for 
California only).

D. Face the ends of the hose clamp to the left.
E. Fasten the canister purge hose and fuel tank 

breather/overflow hose with the holder 70 mm (2.76 
in) from the hose joints on the canister (for 
California only).

F. Install the cylinder-#2 intake air pressure sensor 

hose onto the throttle body pipe up to the bend in 
the pipe, making sure to face the white paint mark 
on the hose upward. Face the ends of the hose 
clamp rearward.

G. Install the canister purge hose onto the throttle 

body pipe up to the bend in the pipe, making sure to 
face the white paint mark on the hose upward (for 
California only).

H. Face the ends of the hose clamp rearward, angled 

to the left.

I.

Align the white paint marks.

J. Align the yellow paint marks.
K. Route the canister purge hose over the air filter 

case joint clamp screw.

CABLE ROUTING

2-59

A

B

B

A

A

B

B

C

D

E

F

G

H

I

J

1

2

3

4

4

5

6

7

8

8

8

9

9

9

10

10

10

11

9 10

12

13

14

15

16

17

18

19

B

CABLE ROUTING

2-60

1. Cylinder-#1 intake air pressure sensor
2. Cylinder-#2 intake air pressure sensor hose
3. Cylinder-#2 intake air pressure sensor
4. ISC (idle speed control) unit coupler
5. ISC (idle speed control) unit
6. Rollover valve 1
7. Rollover valve 2
8. ISC (idle speed control) unit inlet hose
9. Cylinder-#1 ISC (idle speed control) unit outlet 

hose

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

hose

11. Hose joint
12. Air filter case breather hose 2
13. Throttle position sensor
14. Throttle body assembly
15. Cylinder-#1 intake air pressure sensor hose
16. Cylinder head breather hose
17. Cylinder-#2 left ignition coil
18. Cylinder-#2 right ignition coil
19. Sub-wire harness 4
A. Face the ends of the hose clamp inward.
B. Face the ends of the hose clamps outward.
C. Install the cylinder-#2 ISC (idle speed control) unit 

outlet hose (hose joint to intake manifold assembly) 
completely onto the intake manifold, making sure to 
face the green paint mark on the hose to the left. 
Face the ends of the hose clamp outward, angled 
45

°

 forward.

D. Install the cylinder-#1 ISC (idle speed control) unit 

outlet hose (hose joint to intake manifold assembly) 
completely onto the intake manifold, making sure to 
face the blue paint mark on the hose to the left.

E. Face the ends of the hose clamp upward.
F. Position the sub-wire harness 4 coupler on top of 

the guide.

G. To the wire harness
H. Install the cylinder-#1 ISC (idle speed control) unit 

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

I.

Install the ISC (idle speed control) unit inlet hose 

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

J. Install the cylinder-#2 ISC (idle speed control) unit 

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

CABLE ROUTING

2-61

3

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE

............................................................................ 3-1

INTRODUCTION....................................................................................... 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL 

SYSTEM................................................................................................... 3-1

GENERAL MAINTENANCE AND LUBRICATION CHART....................... 3-1

ENGINE

........................................................................................................... 3-4

ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
SYNCHRONIZING THE THROTTLE BODIES ......................................... 3-7
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-8
CHECKING THE SPARK PLUGS............................................................. 3-9
CHECKING THE IGNITION TIMING....................................................... 3-10
CHECKING THE ENGINE OIL LEVEL ................................................... 3-11
CHANGING THE ENGINE OIL ............................................................... 3-11
CHECKING THE TRANSFER GEAR OIL LEVEL................................... 3-13
CHANGING THE TRANSFER GEAR OIL .............................................. 3-14
CHECKING THE CLUTCH FLUID LEVEL .............................................. 3-14
BLEEDING THE HYDRAULIC CLUTCH SYSTEM................................. 3-15
REPLACING THE AIR FILTER ELEMENT ............................................. 3-15
CHECKING THE THROTTLE BODY JOINTS ........................................ 3-16
CHECKING THE FUEL LINE .................................................................. 3-16
CHECKING THE CYLINDER HEAD BREATHER HOSE ....................... 3-17
CHECKING THE OIL TANK BREATHER HOSE .................................... 3-17
CHECKING THE EXHAUST SYSTEM ................................................... 3-17
CHECKING THE CANISTER (for California only)................................... 3-18
ADJUSTING THE EXUP CABLES.......................................................... 3-18

CHASSIS

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

ADJUSTING THE REAR DISC BRAKE .................................................. 3-20
CHECKING THE BRAKE FLUID LEVEL ................................................ 3-20
CHECKING THE FRONT BRAKE PADS................................................ 3-21
CHECKING THE REAR BRAKE PADS .................................................. 3-21
CHECKING THE FRONT BRAKE HOSES ............................................. 3-21
CHECKING THE REAR BRAKE HOSES ............................................... 3-22
ADJUSTING THE REAR BRAKE LIGHT SWITCH................................. 3-22
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-22
ADJUSTING THE SHIFT PEDAL............................................................ 3-23
ADJUSTING THE DRIVE BELT SLACK ................................................. 3-24
CHECKING AND ADJUSTING THE STEERING HEAD......................... 3-25
CHECKING THE FRONT FORK............................................................. 3-26
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-27
CHECKING THE TIRES ......................................................................... 3-27
CHECKING THE WHEELS ..................................................................... 3-29
CHECKING AND LUBRICATING THE CABLES .................................... 3-29
LUBRICATING THE LEVERS................................................................. 3-30
LUBRICATING THE PEDAL ................................................................... 3-30
LUBRICATING THE SIDESTAND .......................................................... 3-30
LUBRICATING THE REAR SUSPENSION ............................................ 3-30

ELECTRICAL SYSTEM

................................................................................ 3-31

CHECKING AND CHARGING THE BATTERY....................................... 3-31
CHECKING THE FUSES ........................................................................ 3-31
REPLACING THE HEADLIGHT BULBS ................................................. 3-31
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-32

PERIODIC MAINTENANCE

3-1

EAS20450

PERIODIC MAINTENANCE

EAS20460

INTRODUCTION

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

EAU17600

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

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

service.

EAU32183

GENERAL MAINTENANCE AND LUBRICATION CHART

No.

ITEM

ROUTINE

INITIAL

ODOMETER READINGS

600 mi 

(1000 km) 

or 

1 month

4000 mi 

(7000 km) 

or 

6 months

8000 mi 

(13000 

km) 

or 

12 months

12000 mi 

(19000 

km) 

or 

18 months

16000 mi 

(25000 

km) 

or 

24 months

20000 mi 

(31000 

km) 

or 

30 months

1

*

Fuel line

• Check fuel hoses for cracks or 

damage.

• Replace if necessary.

√

√

√

√

√

2

*

Spark plugs

• Check condition.
• Adjust gap and clean.
• Replace every 8000 mi 

(13000 km) or 12 months.

√

Replace.

√

Replace.

√

3

*

Valve clearance

• Check and adjust valve clear-

ance when engine is cold.

• Adjust if necessary.

Every 16000 mi (25000 km)

4

*

Crankcase 
breather system

• Check breather hose for 

cracks or damage.

• Replace if necessary.

√

√

√

√

√

5

*

Fuel injection

• Adjust synchronization.

√

√

√

√

√

6

*

Exhaust system

• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if neces-

sary.

√

√

√

√

√

7

*

Evaporative emis-
sion control sys-
tem (For 
California only)

• Check control system for 

damage.

• Replace if necessary.

√

√

No.

ITEM

ROUTINE

INITIAL

ODOMETER READINGS

600 mi 

(1000 km) 

or 

1 month

4000 mi 

(7000 km) 

or 

6 months

8000 mi 

(13000 

km) 

or 

12 months

12000 mi 

(19000 

km) 

or 

18 months

16000 mi 

(25000 

km) 

or 

24 months

20000 mi 

(31000 

km) 

or 

30 months

1

*

Air filter element

• Check condition and damage.
• Replace if necessary.

√

√

√

√

√

2

*

Clutch

• Check operation and fluid 

leakage.

• Correct if necessary.

√

√

√

√

√

√

3

*

Front brake

• Check operation, fluid level, 

and for fluid leakage.

• Replace brake pads if neces-

sary.

√

√

√

√

√

√

4

*

Rear brake

• Check operation, fluid level, 

and for fluid leakage.

• Replace brake pads if neces-

sary.

√

√

√

√

√

√

5

*

Brake hoses

• Check for cracks or damage.

√

√

√

√

√

• Replace.

Every 4 years

PERIODIC MAINTENANCE

3-2

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

service.

6

*

Wheels

• Check runout and for dam-

age.

• Replace if necessary.

√

√

√

√

√

7

*

Tires

• Check tread depth and for 

damage.

• Replace if necessary.
• Check air pressure.
• Correct if necessary.

√

√

√

√

√

8

*

Wheel bearings

• Check bearings for smooth 

operation.

• Replace if necessary.

√

√

√

√

√

9

*

Swingarm pivot 
bearings

• Check bearing assemblies for 

looseness.

√

√

√

√

√

10

*

Drive belt

• Check belt tension.
• Adjust if necessary.

√

Every 2500 mi (4000 km)

11

*

Steering bearings

• Check bearing assemblies for 

looseness.

• Moderately repack with lithi-

um-soap-based grease every 
16000 mi (25000 km) or 24 
months.

√

√

√

√

Repack.

√

12

*

Chassis fasteners

• Check all chassis fitting and 

fasteners.

• Correct if necessary.

√

√

√

√

√

13

Brake and clutch 
lever pivot shafts

• Apply lithium-soap-based 

grease (all-purpose grease) 
lightly.

√

√

√

√

√

14

Brake and shift 
pedal pivot shafts

• Apply lithium-soap-based 

grease (all-purpose grease) 
lightly.

√

√

√

√

√

15

Sidestand pivot

• Check operation.
• Apply lithium-soap-based 

grease (all-purpose grease) 
lightly.

√

√

√

√

√

16

*

Sidestand switch

• Check operation and replace 

if necessary.

√

√

√

√

√

√

17

*

Front fork

• Check operation and for oil 

leakage.

• Replace if necessary.

√

√

√

√

√

18

*

Shock absorber 
assembly

• Check operation and for oil 

leakage.

• Replace if necessary.

√

√

√

√

√

19

*

Rear suspension 
link pivots

• Apply lithium-soap-based 

grease lightly.

√

20

Engine oil

• Change (warm engine before 

draining).

√

√

√

√

√

√

21

*

Engine oil filter 
cartridge

• Replace.

√

√

√

22

*

Transfer case oil

• Check for leakage.
• Change at initial 600 mi (1000 

km) or 1 month, and thereaf-
ter every 16000 mi (25000 
km) or 24 months.

Change.

√

Change.

23

*

Front and rear 
brake switches

• Check operation.

√

√

√

√

√

√

24

*

Control cables

• Apply Yamaha chain and ca-

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

√

√

√

√

√

√

25

*

Throttle grip 
housing and ca-
ble

• Check operation and free 

play.

• Adjust the throttle cable free 

play if necessary.

• Lubricate the throttle grip 

housing and cable.

√

√

√

√

√

26

*

Lights, signals 
and switches

• Check operation.
• Adjust headlight beam.

√

√

√

√

√

√

No.

ITEM

ROUTINE

INITIAL

ODOMETER READINGS

600 mi 

(1000 km) 

or 

1 month

4000 mi 

(7000 km) 

or 

6 months

8000 mi 

(13000 

km) 

or 

12 months

12000 mi 

(19000 

km) 

or 

18 months

16000 mi 

(25000 

km) 

or 

24 months

20000 mi 

(31000 

km) 

or 

30 months

PERIODIC MAINTENANCE

3-3

NOTE:

From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi 
(13000 km) or 12 months.

EAU38440

NOTE:

• Air filter

• This model’s air filter is equipped with a disposable oil-coated paper element, which must not be 

cleaned with compressed air to avoid damaging it.

• The air filter element needs to be replaced more frequently when riding in unusually wet or dusty 

areas.

• Hydraulic brake and clutch systems

• After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder, 

always change the fluid. Regularly check the brake and clutch fluid levels and fill the reservoirs as 
required.

• Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and 

clutch release cylinder every two years.

• Replace the brake and clutch hoses every four years or if cracked or damaged.

ENGINE

3-4

EAS20470

ENGINE

EAS20530

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the 
valves.

NOTE:

• The valve clearance is automatically adjusted 

by the hydraulic valve lifter. However, there are 
times when the valve clearance needs to be 
adjusted manually. If this is the case, adjust the 
clearance of the two maladjusted or worn 
valves using the adjusting screw on the rocker 
arm.
If clearance is on the slip side “1”, loosen the 
adjusting screw and bring the valve clearance 
“a” within specification. Check if the valve 
clearance “b” on the adjusting screw “2” side is 
within specification.

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

• Valve clearance adjustment should be made 

on a cold engine, at room temperature.

• When the valve clearance is to be measured or 

adjusted, the piston must be at top dead center 
(TDC) on the compression stroke.

1. Remove:

• Rider seat
• Rider seat bracket assembly

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

• Fuel tank

Refer to “FUEL TANK” on page 6-1.

• Air filter case

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

• Muffler
• Exhaust pipes

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

2. Disconnect:

• Spark plug caps

3. Remove:

• Spark plugs

4. Remove:

• Shift pedal assembly “1”

5. Remove:

• Damper cover “1”
• Damper “2”
• Timing mark accessing screw “3”
• Crankshaft end screw “4”

6. Remove:

• Camshaft sprocket cover “1”

7. Remove:

• Wire harness guide bolt “1”

1

3

4

2

1

1

ENGINE

3-5

8. Remove:

• Fuel tank damper “1”
• Cylinder head breather hose “2”

9. Disconnect:

• Oil tank breather hose “3”
• Fuel outlet hose “4”

10.Remove:

• Front cylinder head cover “1”
• Rear cylinder head cover “2”

NOTE:

Due to the small clearance between the frame 
and the rear cylinder head cover, the three bolts 
“3” cannot be removed when the cover is in 
place. Loosen the bolts, and then remove the 
cylinder head cover from the right side of the ve-
hicle, making sure that the bolts do not scratch 
the rocker arms or other engine parts.

11.Measure:

• Valve clearance

Out of specification 

→

 Adjust.

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

Piston #1 TDC (rear cylinder)

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.

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).

1

1

2

3

4

2

1

 

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)

2

3

3

b

a

ENGINE

3-6

d. Measure the valve clearance with a thickness 

gauge.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

Piston #2 TDC (front cylinder)

a. Turn the crankshaft counterclockwise from 

the piston #1 TDC by 408 degrees.

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

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

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

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

d. Measure the valve clearance with a thickness 

gauge.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

12.Adjust:

• Valve clearance

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Loosen the locknut “1”.

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

of the adjusting screw and the valve tip.

c. Turn the adjusting screw “3” in direction “a” or 

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

 

Thickness gauge

90890-03180

Feeler gauge set

YU-26900-9

d

c

b

e

d

c

 

Thickness gauge

90890-03180

Feeler gauge set

YU-26900-9

 

Thickness gauge

90890-03180

Feeler gauge set

YU-26900-9

 

Tappet adjusting tool (4 mm)

90890-04133

Valve adjustment wrench 3 mm & 
4 mm

YM-08035-A

Adjusting 

screw side

Slip side

Direction “a”

Valve clear-
ance is in-
creased.

Valve clear-
ance is de-
creased.

Direction “b”

Valve clear-
ance is de-
creased.

Valve clear-
ance is in-
creased.

1

ENGINE

3-7

d. Hold the adjusting screw to prevent it from 

moving and tighten the locknut to specifica-
tion.

e. Measure the valve clearance again.
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.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

13.Install:

• All removed parts

Refer to “CAMSHAFTS” on page 5-14.

NOTE:

For installation, reverse the removal procedure. 

EAS20570

SYNCHRONIZING THE THROTTLE BODIES

NOTE:

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

1. Stand the vehicle on a level surface.

NOTE:

Place the vehicle on a suitable stand.

2. Remove:

• Rider seat
• Rider seat bracket assembly

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

• Cylinder-#1 ignition coil cover

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

• Fuel tank

Refer to “FUEL TANK” on page 6-1.

3. Remove:

• Cylinder-#1 intake air pressure sensor brack-

et “1”

• Cylinder-#2 intake air pressure sensor brack-

et “2”

4. Disconnect:

• Cylinder-#1 intake air pressure sensor hose 

“1”

• Cylinder-#2 intake air pressure sensor hose 

“2”

5. Install:

• Hose “1” (Parts No.: 5JW-24311-00)
• 3-way joint “2” (Parts No.: 90413-05014)
• Vacuum gauge hose for #1 “3”
• Vacuum gauge hose for #2 “4”
• Cylinder-#1 intake air pressure sensor hose 

“5”

• Cylinder-#2 intake air pressure sensor hose 

“6”

• Vacuum gauge
• Tachometer

T

 

R

.

 

Locknut (rocker arm adjusting 
screw)

20 Nm (2.0 m·kg, 14 ft·lb)

 

Tappet adjusting tool (4 mm)

90890-04133

Valve adjustment wrench 3 mm & 
4 mm

YM-08035-A

4

3

a

b

2

 

Vacuum gauge

90890-03094

Carburetor synchronizer

YU-44456

1

2

2

1

ENGINE

3-8

6. Install:

• Fuel tank

Refer to “FUEL TANK” on page 6-1.

7. Adjust:

• Throttle body synchronization

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

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

minutes, and then let it run at specified en-
gine idling speed.

b. With throttle body #1 as standard, adjust 

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

NOTE:

• After each step, rev the engine two or three 

times, each time for less than a second, and 
check the synchronization again.

• If the air screw was removed, turn the screw 

3/4 turn in and be sure to synchronize the throt-
tle body.

CAUTION:

ECA14900

Do not use the throttle valve adjusting 
screws to adjust the throttle body synchroni-
zation.

NOTE:

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

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

8. Stop the engine and remove the measuring 

equipment.

9. Adjust:

• Throttle cable free play

Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-8.

10.Install:

• Fuel tank

Refer to “FUEL TANK” on page 6-1.

• Cylinder-#1 ignition coil cover

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

• Rider seat bracket assembly
• Rider seat

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

EAS20630

ADJUSTING THE THROTTLE CABLE FREE 
PLAY

NOTE:

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

1. Check:

• Throttle cable free play “a”

Out of specification 

→

 Adjust.

2. Adjust:

• Throttle cable free play

 

Engine idling speed

850–950 r/min

 

Intake vacuum

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

1

4

6

2

1

3

5

2

1

 

Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)

 

Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)

a

ENGINE

3-9

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

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

until the specified throttle cable free play is 
obtained.

c. Tighten the locknut “1”.

WARNING

EWA12910

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
• Rider seat bracket assembly

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

• Fuel tank

Refer to “FUEL TANK” on page 6-1.

• Air filter case

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

2. Disconnect:

• Spark plug cap

3. Remove:

• Spark plug

CAUTION:

ECA13320

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

4. Check:

• Spark plug type

Incorrect 

→

 Change.

5. Check:

• Electrode “1”

Damage/wear 

→

 Replace the spark plug.

• Insulator “2”

Abnormal color 

→

 Replace the spark plug.

Normal color is medium-to-light tan.

6. Clean:

• Spark plug

(with a spark plug cleaner or wire brush)

7. Measure:

• Spark plug gap “a”

(with a wire thickness gauge)
Out of specification 

→

 Regap.

8. Install:

• Spark plug

NOTE:

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

9. Connect:

• Spark plug cap

Direction “a”

Throttle cable free play is increased.

Direction “b”

Throttle cable free play is decreased.

a

b

1

2

 

Manufacturer/model

NGK/DPR8EA-9

Manufacturer/model

DENSO/X24EPR-U9

 

Spark plug gap

0.8–0.9 mm (0.031–0.035 in)

T

 

R

.

 

Spark plug

18 Nm (1.8 m·kg, 13 ft·lb)