Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 7

• Fuel tank

• Rider seat bracket assembly
• Rider seat

EAS20700

CHECKING THE IGNITION TIMING

NOTE:

Prior to checking the ignition timing, check the
wiring connections of the entire ignition system.
Make sure all connections are tight and free of
corrosion.

1. Stand the vehicle on a level surface.
2. Remove:

• Shift pedal assembly “1”

3. Remove:

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

4. Connect:

• Timing light “1”
• Tachometer

5. Check:

• Ignition timing

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a. Start the engine, warm it up for several min-

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

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

system.

NOTE:

The ignition timing is not adjustable.

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6. Install:

• Timing mark accessing screw
• Damper
• Damper cover

7. Install:

• Shift pedal assembly “1”

Timing light

90890-03141

Inductive clamp timing light

YU-03141

3 2

Engine idling speed

850–950 r/min

Damper cover bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

Shift pedal bolt

18 Nm (1.8 m·kg, 13 ft·lb)

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ENGINE

3-11

NOTE:

Align the mark “a” on the shift pedal shaft with
the slot in the shift pedal.

EAS20750

CHECKING THE ENGINE OIL LEVEL

1. Stand the vehicle on a level surface.

NOTE:

• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.

2. Start the engine, warm it up for approximately

15 minutes until the oil temperature rises to
60 °C (140 °F), and then turn it off.

3. Remove:

• Rider seat

4. Remove:

• Dipstick “1”

5. Check:

• Engine oil level

The engine oil level should be between the
minimum level mark “a” and maximum level
mark “b”.
Below the minimum level mark

→

Add the

recommended engine oil to the proper level.

NOTE:

• Before checking the engine oil level, wait a few

minutes until the oil has settled.

• Do not screw the dipstick in when inspecting

the oil level.

CAUTION:

ECA13380

• Engine oil also lubricates the clutch and the

wrong oil types or additives could cause
clutch slippage. Therefore, do not add any
chemical additives.

• Do not allow foreign materials to enter the

crankcase.

6. Start the engine, warm it up for several min-

utes, and then turn it off.

7. Check the engine oil level again.

NOTE:

Before checking the engine oil level, wait a few
minutes until the oil has settled.

8. Install:

• Dipstick

9. Install:

• Rider seat

Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-11.

EAS20780

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-

utes, and then turn it off.

2. Place a container under the engine oil drain

bolts.

3. Remove:

• Engine oil filler cap “1”

4. Remove:

• Engine oil drain bolt (oil tank) “1”

(along with the gasket)

Type

YAMALUBE 4 (20W40) or
SAE20W40

Recommended engine oil grade

API service SG type or higher,
JASO standard MA

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ENGINE

3-12

5. Remove:

• Engine oil drain bolts (crankcase) “1”

(along with the gaskets)

6. Drain:

• Engine oil

(completely from the oil tank and crankcase)

7. If the oil filter cartridge is also to be replaced,

perform the following procedure.

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a. Remove the oil filter cartridge “1” with an oil

filter wrench “2”.

b. Lubricate the O-ring “3” of the new oil filter

cartridge with a thin coat of engine oil.

CAUTION:

ECA13390

Make sure the O-ring “3” is positioned cor-
rectly in the groove of the oil filter cartridge.

c. Tighten the new oil filter cartridge to specifi-

cation with an oil filter wrench.

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8. Check:

• Engine oil drain bolt gaskets

Damage

→

Replace.

9. Install:

• Engine oil drain bolt (oil tank)

(along with the gasket)

10.Install:

• Engine oil drain bolts (crankcase)

(along with the gaskets)

11.Fill:

• Oil tank

(with the specified amount of the recom-
mended engine oil)

NOTE:

Pour the engine oil in two stages. First, pour in
2.5 L of oil, then start the engine and rev it 3 to 5
times. Stop the engine, and then pour in the re-
mainder of the specified amount.

Oil filter wrench

90890-01426
YU-38411

Oil filter cartridge

17 Nm (1.7 m·kg, 12 ft·lb)

Engine oil drain bolt (oil tank)

43 Nm (4.3 m·kg, 31 ft·lb)

Engine oil drain bolt (crankcase)

43 Nm (4.3 m·kg, 31 ft·lb)

Engine oil quantity

Total amount

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-
ment

4.90 L (5.18 US qt) (4.31 Imp.qt)

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ENGINE

3-13

CAUTION:

EC1D71008

When starting the engine make sure the dip-
stick is securely fitted into the oil tank.

12.Fill: (when engine is disassembled)

• Crankcase and oil tank

(with the specified amount of the recom-
mended engine oil)

13.Install:

• Engine oil filler cap

14.Start the engine, warm it up for several min-

utes, and then turn it off.

15.Check:

• Engine

(for engine oil leaks)

16.Check:

• Engine oil level

17.Check:

• Engine oil pressure

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a. Slightly loosen the oil gallery bolts “1”.

b. Start the engine and keep it idling until engine

oil starts to seep from the oil gallery bolts. If
no engine oil comes out after one minute, turn
the engine off so that it will not seize.

c. Check the engine oil passages, the oil filter

cartridge and the oil pump for damage or
leakage. Refer to “OIL PUMP” on page 5-95.

d. Start the engine after solving the problem(s)

and check the engine oil pressure again.

e. Tighten the oil gallery bolts to specification.

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EAS20840

CHECKING THE TRANSFER GEAR OIL
LEVEL

1. Stand the vehicle on a level surface.

NOTE:

• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.

2. Remove:

• Transfer gear oil check bolt “1”

3. Check:

• 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.

CAUTION:

EC1D71024

Do not allow foreign materials to enter the
transfer gear case.

4. Install:

• Transfer gear oil check bolt

Engine oil quantity

Total amount

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)

Oil gallery bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

Type

SAE80 API GL-4 Hypoid gear oil

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ENGINE

3-14

EAS20850

CHANGING THE TRANSFER GEAR OIL

1. Remove:

• Muffler
• Exhaust pipes

Refer to “CHECKING THE TRANSFER
GEAR OIL LEVEL” on page 3-13.

2. Place a container under the transfer gear oil

drain bolt.

3. Remove:

• Straight plug “1”
• Transfer gear oil drain bolt “2”

4. Drain:

• Transfer gear oil

(completely from the transfer gear case)

5. Check:

• Transfer gear oil drain bolt gasket

Damage

→

Replace.

6. Install:

• Transfer gear oil drain bolt

(along with the gasket)

7. Fill:

• Transfer gear case

(with the specified amount of the recom-
mended transfer gear oil)

8. Install:

• Straight plug

9. Check:

• Transfer gear oil level

10.Install:

• Exhaust pipes
• Muffler

EAS20890

CHECKING THE CLUTCH FLUID LEVEL

1. Stand the vehicle on a level surface.

NOTE:

Place the vehicle on a suitable stand.

2. Check:

• Clutch fluid level

Below the minimum level mark “a”

→

Add the

recommended clutch fluid to the proper level.

WARNING

EWA13370

• Use only the designated clutch fluid. Other

clutch fluids may cause the rubber seals to
deteriorate, causing leakage and poor
clutch performance.

Transfer gear oil check bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)

Transfer gear oil drain bolt

18 Nm (1.8 m·kg, 13 ft·lb)

Quantity

0.55 L (0.58 US qt) (0.48 Imp.qt)

Quantity (disassembled)

0.60 L (0.63 US qt) (0.53 Imp.qt)

Recommended clutch fluid

Brake fluid DOT 4

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ENGINE

3-15

• Refill with the same type of clutch fluid that

is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.

• 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.

CAUTION:

ECA13420

Clutch fluid may damage painted surfaces or
plastic parts. Therefore, always clean up any
spilt clutch fluid immediately.

NOTE:

In order to ensure a correct reading of the clutch
fluid level, make sure the top of the reservoir is
horizontal.

EAS20900

BLEEDING THE HYDRAULIC CLUTCH
SYSTEM

WARNING

EWA13000

Bleed the hydraulic clutch system whenever:
• the system was disassembled,
• a clutch hose was loosened or removed,
• the clutch fluid level is very low,
• clutch operation is faulty.

NOTE:

• Be careful not to spill any clutch fluid or allow

the clutch master cylinder reservoir to over-
flow.

• When bleeding the hydraulic clutch system,

make sure there is always enough clutch fluid
before applying the clutch lever. Ignoring this
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

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a. Add the recommended clutch fluid to the

proper level.

b. Install the clutch master cylinder reservoir di-

aphragm.

c. Connect a clear plastic hose “1” tightly to the

bleed screw “2”.

d. Place the other end of the hose into a con-

tainer.

e. Slowly squeeze the clutch lever several

times.

f. Fully squeeze the clutch lever without releas-

ing it.

g. Loosen the bleed screw. This will release the

tension and cause the clutch lever to contact
the handlebar grip.

h. Tighten the bleed screw and then release the

clutch lever.

i. Repeat steps (e) to (h) until all of the air bub-

bles have disappeared from the clutch fluid in
the plastic hose.

j. Tighten the bleed screw to specification.

k. Add the recommended clutch fluid to the

proper level.
Refer to “CHECKING THE CLUTCH FLUID
LEVEL” on page 3-14.

WARNING

EWA13010

After bleeding the hydraulic clutch system,
check the clutch operation.

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EAS20960

REPLACING THE AIR FILTER ELEMENT

1. Remove:

• Rider seat

2. Remove:

• Fuel tank

3. Remove:

• Air filter case cover “1”

Bleed screw (clutch release cylin-
der)

6 Nm (0.6 m·kg, 4.3 ft·lb)

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ENGINE

3-16

4. Remove:

• Air filter element “1”

5. Check:

• Air filter element

Damage

→

Replace.

NOTE:

The air filter needs more frequent service if you
are riding in unusually wet or dusty areas.

6. Install:

• Air filter case cover

CAUTION:

EC1D71002

Never operate the engine without the air filter
element installed. Unfiltered air will cause
rapid wear of engine parts and may damage
the engine. Operating the engine without the
air filter element will also affect the throttle
body synchronization, leading to poor en-
gine performance and possible overheating.

NOTE:

When installing the air filter element into the air
filter case, make sure that the sealing surfaces
are aligned to prevent any air leaks.

7. Install:

• Fuel tank

• Rider seat

EAS21010

CHECKING THE THROTTLE BODY JOINTS

The following procedure applies to all of the
throttle body joints and intake manifolds.
1. Remove:

• Rider seat
• Rider seat bracket assembly

• Fuel tank

• Air filter case

2. Check:

• Throttle body joints “1”

Cracks/damage

→

Replace.

3. Install:

• Air filter case

• Fuel tank

• Rider seat bracket assembly
• Rider seat

EAS21030

CHECKING THE FUEL LINE

The following procedure applies to all of the fuel,
air vent and breather hoses.
1. Remove:

• Rider seat
• Rider seat bracket assembly

• Fuel tank

2. Check:

• Fuel hoses “1”
• Air vent hose “2”
• Breather hose “3”

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

CAUTION:

ECA14940

Make sure the fuel tank breather hose is rout-
ed correctly.

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ENGINE

3-17

3. Install:

• Fuel tank

• Rider seat bracket assembly
• Rider seat

EAS21050

CHECKING THE CYLINDER HEAD
BREATHER HOSE

1. Remove:

• Rider seat
• Rider seat bracket assembly

• Fuel tank

• Air filter case

2. Check:

• Cylinder head breather hose “1”

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

CAUTION:

ECA14920

Make sure the cylinder head breather hose is
routed correctly.

3. Install:

• Air filter case

• Fuel tank

• Rider seat bracket assembly
• Rider seat

EAS21060

CHECKING THE OIL TANK BREATHER
HOSE

1. Remove:

• Right side cover

2. Check:

• Oil tank breather hose “1”

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

CAUTION:

ECA14930

Make sure the oil tank breather hose is rout-
ed correctly.

3. Install:

• Right side cover

Refer to “THROTTLE BODIES” on page 6-6.

EAS21080

CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex-
haust pipes and gaskets.
1. Check:

• Front exhaust pipe “1”
• Rear exhaust pipe “2”

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ENGINE

3-18

• Muffler “3”
• Muffler bracket “4”

Cracks/damage

→

Replace.

• Gaskets “5”

Exhaust gas leaks

→

Replace.

2. Check:

Tightening torque

• Front exhaust pipe nuts “6”
• Front exhaust pipe and rear exhaust pipe bolt

“7”

• Rear exhaust pipe nuts “8”
• Rear exhaust pipe and muffler bolt “9”
• Muffler and muffler bracket bolts “10”
• Muffler bracket and frame bolts “11”

EAS21090

CHECKING THE CANISTER (for California
only)

1. Remove:

• Horn 1

2. Check:

• Canister “1”
• Canister purge hose “2”
• Canister breather hose “3”
• Fuel tank breather/overflow hose “4”

Cracks/damage

→

Replace.

3. Install:

• Horn 1

Refer to “THROTTLE BODIES” on page 6-6.

EAS21100

ADJUSTING THE EXUP CABLES

1. Remove:

• EXUP valve pulley cover “1”

2. Check:

• EXUP system operation

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a. Turn the main switch to “ON”.
b. Check that the EXUP valve operates proper-

ly.

NOTE:

Check that the projection “a” on the EXUP valve
pulley contact the stopper “b” (fully-open posi-
tion) and the stopper “c” (fully-closed position).

Front exhaust pipe nut

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)

Rear exhaust pipe nut

24 Nm (2.4 m·kg, 17 ft·lb)

Rear exhaust pipe and muffler
bolt

20 Nm (2.0 m·kg, 14 ft·lb)

Muffler and muffler bracket bolt

29 Nm (2.9 m·kg, 21 ft·lb)

Muffler bracket and frame bolt

53 Nm (5.3 m·kg, 38 ft·lb)
LOCTITE

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ENGINE

3-19

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3. Check:

• EXUP cable free play (at the EXUP valve pul-

ley) “a” and “b”

4. Adjust:

• EXUP cable free play

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a. Loosen both locknuts “1”.

b. Turn both adjusting bolts “2” in or out until the

specification.

c. Tighten both locknuts.
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
lines “d” on the cable holder.

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5. Install:

• EXUP valve pulley cover

EXUP cable free play (at the
EXUP valve pulley)

a: 3 mm (0.12 in) or less
b: 3 mm (0.12 in) or less

Turn in “a”

→

Free play is increased.

Turn out “b”

→

Free play is decreased.

EXUP valve pulley cover bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)

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CHASSIS

3-20

EAS21140

CHASSIS

EAS21190

ADJUSTING THE REAR DISC BRAKE

1. Check:

• Brake pedal position

(distance “a” from the top of the rider footrest
to the top of the brake pedal)
Out of specification

→

Adjust.

2. Adjust:

• Brake pedal position

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

“b” until the specified brake pedal position is
obtained.

WARNING

EWA13070

After adjusting the brake pedal position,
check that the end of the adjusting bolt “c” is
visible through the hole “d”.

c. Tighten the locknut.

WARNING

EW1D71005

A soft or spongy feeling in the brake pedal
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.

CAUTION:

ECA13510

After adjusting the brake pedal position,
make sure there is no brake drag.

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3. Adjust:

• Rear brake light switch

Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” on page 3-22.

EAS21240

CHECKING THE BRAKE FLUID LEVEL

1. Stand the vehicle on a level surface.

NOTE:

• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.

2. Remove:

• Rider seat

3. Check:

• Brake fluid level

Below the minimum level mark “a”

→

Add the

recommended brake fluid to the proper level.

Brake pedal position

110.0 mm (4.33 in)

Direction “a”

Brake pedal is raised.

Direction “b”

Brake pedal is lowered.

Front brake

Recommended fluid

DOT 4

Rear brake

Recommended fluid

DOT 4

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CHASSIS

3-21

WARNING

EWA13090

• Use only the designated brake fluid. Other

brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.

• 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.

• When refilling, be careful that water does

not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor lock.

CAUTION:

ECA13540

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean up
any spilt brake fluid immediately.

NOTE:

In order to ensure a correct reading of the brake
fluid level, make sure the top of the brake fluid
reservoir is horizontal.

4. Install:

• Rider seat

Refer to “FRONT BRAKE” on page 4-31.

EAS21250

CHECKING THE FRONT BRAKE PADS

The following procedure applies to all of the
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.

EAS21260

CHECKING THE REAR BRAKE PADS

The following procedure applies to all of the
brake pads.
1. Operate the brake.
2. Check:

• Rear brake pad

Wear indicators “1” almost touch the brake
disc

→

Replace the brake pads as a set.

Refer to “REAR BRAKE” on page 4-43.

EAS21280

CHECKING THE FRONT BRAKE HOSES

The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:

• Brake hoses “1”

Cracks/damage/wear

→

Replace.

A. Front brake
B. Rear brake

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CHASSIS

3-22

2. Check:

• Brake hose clamps

Loose

→

Tighten the clamp bolt.

3. Hold the vehicle upright and apply the brake

several times.

4. Check:

• Brake hoses

Brake fluid leakage

→

Replace the damaged

hose.
Refer to “FRONT BRAKE” on page 4-31.

EAS21290

CHECKING THE REAR BRAKE HOSES

1. Remove:

• Rider seat

2. Check:

• Brake hoses “1”

Cracks/damage/wear

→

Replace.

3. Check:

• Brake hose clamp

Loose connection

→

Tighten the clamp bolt.

4. Check:

• Brake hose guide

Loose

→

Tighten the guide bolt.

5. Hold the vehicle upright and apply the brake

several times.

6. Check:

• Brake hoses

Brake fluid leakage

→

Replace the damaged

hose.
Refer to “REAR BRAKE” on page 4-43.

EAS21330

ADJUSTING THE REAR BRAKE LIGHT
SWITCH

NOTE:

The rear brake light switch is operated by move-
ment of the brake pedal. The rear brake light
switch is properly adjusted when the brake light
comes on just before the braking effect starts.

1. Check:

• Rear brake light operation timing

Incorrect

→

Adjust.

2. Adjust:

• Rear brake light operation timing

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a. Hold the main body “1” of the rear brake light

switch so that it does not rotate and turn the
adjusting nut “2” in direction “a” or “b” until the
rear brake light comes on at the proper time.

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EAS21350

BLEEDING THE HYDRAULIC BRAKE
SYSTEM

WARNING

EWA13100

Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or

replaced.

• the brake fluid level is very low.
• brake operation is faulty.

1. Remove:

• Rider seat

Direction “a”

Brake light comes on sooner.

Direction “b”

Brake light comes on later.

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CHASSIS

3-23

NOTE:

• Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir or brake
fluid reservoir to overflow.

• When bleeding the hydraulic brake system,

make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.

• If bleeding is difficult, it may be necessary to let

the brake fluid settle for a few hours. Repeat
the bleeding procedure when the tiny bubbles
in the hose have disappeared.

2. Bleed:

• Hydraulic brake system

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a. Fill the brake fluid reservoir to the proper level

with the recommended brake fluid.

b. Install the diaphragm (brake master cylinder

reservoir or brake fluid reservoir).

c. Connect a clear plastic hose “1” tightly to the

bleed screw “2”.

d. Place the other end of the hose into a con-

tainer.

e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down

the brake pedal and hold it in position.

g. Loosen the bleed screw.

NOTE:

Loosening the bleed screw will release the pres-
sure and cause the brake lever to contact the
throttle grip or the brake pedal to fully extend.

h. Tighten the bleed screw and then release the

brake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the air bub-

bles have disappeared from the brake fluid in
the plastic hose.

j. Tighten the bleed screw to specification.

k. Fill the brake fluid reservoir to the proper level

with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” on page 3-20.

WARNING

EWA13110

After bleeding the hydraulic brake system,
check the brake operation.

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3. Install:

• Rider seat

EAS21380

ADJUSTING THE SHIFT PEDAL

NOTE:

The shift pedal position is determined by the in-
stalled shift rod length “a”.

1. Measure:

• Installed shift rod length “a”

Incorrect

→

Adjust.

2. Adjust:

• Installed shift rod length

A. Front
B. Rear

Bleed screw (front brake caliper)

6 Nm (0.6 m·kg, 4.3 ft·lb)

Bleed screw (rear brake caliper)

6 Nm (0.6 m·kg, 4.3 ft·lb)

Installed shift rod length

312.0–316.0 mm (12.28–12.44 in)

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CHASSIS

3-24

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a. Loosen both locknuts “1”.
b. Turn the shift rod “2” in direction “a” or “b” until

the specified installed shift rod length is ob-
tained.

NOTE:

Make sure that the exposed thread length “c” be-
tween the locknut and joint on both ends of the
shift rod is 10 mm or less.

c. Tighten both locknuts.

d. Make sure the installed shift rod length is

within specification.

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EAS21430

ADJUSTING THE DRIVE BELT SLACK

NOTE:

The drive belt slack must be checked at the tight-
est point on the belt.

CAUTION:

ECA14950

A drive belt that is too tight will overload the
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.

NOTE:

Measure the drive belt slack when the engine is
cold, and when the drive belt is dry.

1. Stand the vehicle on a level surface.

WARNING

EWA13120

Securely support the vehicle so that there is
no danger of it falling over.

NOTE:

Place the vehicle on the sidestand and or on a
suitable stand so that the rear wheel is elevated.

2. Check:

• Drive belt slack “a”

Out of specification

→

Adjust.

NOTE:

• 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.

• Measure the drive belt slack when the drive

belt has been pushed with 4.5 kg (10 lbs) of
pressure using a belt tension gauge “1”.

Direction “a”

Installed shift rod length increases.

Direction “b”

Installed shift rod length decreases.

Locknut (shift rod)

12 Nm (1.2 m·kg, 8.7 ft·lb)

Drive belt slack (on the side-
stand)

7.5–13 mm (0.30–0.51 in)

Drive belt slack (on a suitable
stand)

14–21 mm (0.55–0.83 in)

Belt tension gauge

90890-03170

Rear drive belt tension gauge

YM-03170

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3. Remove:

• Muffler

4. Adjust:

• Drive belt slack

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NOTE:

Place the vehicle on a suitable stand so that the
rear wheel is elevated.

a. Loosen the wheel axle nut “1”.

b. Loosen both locknuts “2”.
c. Turn both adjusting bolts “3” in direction “a” or

“b” until the specified drive belt slack is ob-
tained.

NOTE:

Using the alignment marks on each side of the
swingarm, make sure that both belt pullers are in
the same position for proper wheel alignment.

d. Tighten the locknuts to specification.

e. Tighten the rear wheel axle nut to specifica-

tion.

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5. Install:

• Muffler