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

CHASSIS

3-26

3. Remove:

• Upper bracket

Refer to “FRONT FORK” on page 4-60.

4. Adjust:

• Steering head

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a. Remove the lock washer “1”, the upper ring

nut “2”, and the rubber washer “3”.

b. Loosen the lower ring nut “4”, and then tight-

en it to the specified torque with a steering nut
wrench “5”.

NOTE:

Set a torque wrench at a right angle to the steer-
ing nut wrench.

c. Loosen the lower ring nut completely, and

then tighten it to specification with a steering
nut wrench.

WARNING

EWA13140

Do not overtighten the lower ring nut.

d. Check the steering head for looseness or

binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” on page 4-69.

e. Install the rubber washer “3”.
f. Install the upper ring nut.
g. Finger tighten the upper ring nut “2”, then

align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.

h. Install the lock washer “1”.

NOTE:

Make sure the lock washer tabs “a” sit correctly
in the ring nut slots “b”.

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5. Install:

• Upper bracket

Refer to “FRONT FORK” on page 4-60.

EAS21530

CHECKING THE FRONT FORK

1. Stand the vehicle on a level surface.

WARNING

EWA13120

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

2. Check:

• Inner tube

Damage/scratches

→

Replace.

• Oil seal

Oil leakage

→

Replace.

Steering nut wrench

90890-01403

Spanner wrench

YU-33975

Lower ring nut (initial tightening
torque)

52 Nm (5.2 m·kg, 37 ft·lb)

Lower ring nut (final tightening
torque)

18 Nm (1.8 m·kg, 13 ft·lb)

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CHASSIS

3-27

3. Hold the vehicle upright and apply the front

brake.

4. Check:

• Front fork operation

Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement

→

Repair.

Refer to “FRONT FORK” on page 4-60.

EAS21590

ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY

WARNING

EWA13120

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

Spring preload

CAUTION:

ECA13590

Never go beyond the maximum or minimum
adjustment positions.

1. Adjust:

• Spring preload

NOTE:

Adjust the spring preload with the special
wrench “1”.

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a. Loosen the locknut “2”.
b. Turn the adjusting ring “3” in direction “a” or

“b”.

c. Tighten the locknut to specification.

CAUTION:

ECA13600

Always tighten the locknut against the ad-
justing nut and torque it to specification.

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EAS21650

CHECKING THE TIRES

The following procedure applies to both of the
tires.
1. Check:

• Tire pressure

Out of specification

→

Regulate.

Direction “a”

Spring preload is increased (suspen-
sion is harder).

Direction “b”

Spring preload is decreased (suspen-
sion is softer).

Spring preload adjusting posi-
tions

Installed spring length

Minimum

162.0 mm (6.38 in)

Standard

XV19S(C)/XV19(C)/XV19M(C):
171.0 mm (6.73 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
165.0 mm (6.50 in)

Maximum

171.0 mm (6.73 in)

c. Installed spring length

Locknut (rear shock absorber
spring preload adjusting nut)

30 Nm (3.0 m·kg, 22 ft·lb)

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CHASSIS

3-28

WARNING

EWA13180

• The tire pressure should only be checked

and regulated when the tire temperature
equals the ambient air temperature.

• The tire pressure and the suspension must

be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.

• Operation of an overloaded vehicle could

cause tire damage, an accident or an injury.

NEVER OVERLOAD THE VEHICLE.

WARNING

EWA13190

It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.

2. Check:

• Tire surfaces

Damage/wear

→

Replace the tire.

WARNING

EWA14080

• Do not use a tubeless tire on a wheel de-

signed only for tube tires to avoid tire fail-
ure and personal injury from sudden
deflation.

• When using a tube tire, be sure to install the

correct tube.

• Always replace a new tube tire and a new

tube as a set.

• To avoid pinching the tube, make sure the

wheel rim band and tube are centered in the
wheel groove.

• Patching a punctured tube is not recom-

mended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality re-
placement.

Tire air pressure (measured on
cold tires)

Loading condition

0–90 kg (0–198 lb)
Front

250 kPa (36 psi) (2.50 kgf/cm²)

Rear

280 kPa (41 psi) (2.80 kgf/cm²)

Loading condition

XV19S(C)/XV19(C)/XV19M(C):
90–210 kg (198–463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
90–186 kg (198–410 lb)
Front

250 kPa (36 psi) (2.50 kgf/cm²)

Rear

280 kPa (41 psi) (2.80 kgf/cm²)

High-speed riding

Front

250 kPa (36 psi) (2.50 kgf/cm²)

Rear

280 kPa (41 psi) (2.80 kgf/cm²)

Maximum load

XV19S(C)/XV19(C)/XV19M(C):
210 kg (463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
186 kg (410 lb)

* Total weight of rider, passenger, cargo

and accessories

Wear limit (front)

1.0 mm (0.04 in)

Wear limit (rear)

1.0 mm (0.04 in)

1. Tire tread depth
2. Side wall
3. Wear indicator

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CHASSIS

3-29

WARNING

EWA14090

After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
approved by Yamaha is used on this vehicle.

WARNING

EWA13210

New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed before
any high-speed riding is done.

NOTE:

For tires with a direction of rotation mark “1”:

• Install the tire with the mark pointing in the di-

rection of wheel rotation.

• Align the mark “2” with the valve installation

point.

EAS21670

CHECKING THE WHEELS

The following procedure applies to both of the
wheels.
1. Check:

• Wheel

Damage/out-of-round

→

Replace.

WARNING

EWA13260

Never attempt to make any repairs to the
wheel.

NOTE:

After a tire or wheel has been changed or re-
placed, always balance the wheel.

EAS21690

CHECKING AND LUBRICATING THE
CABLES

The following procedure applies to all of the in-
ner and outer cables.

WARNING

EWA13270

Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.

1. Check:

• Outer cable

Damage

→

Replace.

2. Check:

• Cable operation

Rough movement

→

Lubricate.

A. Tire
B. Wheel

Tube wheel

Tube tire only

Tubeless wheel

Tube or tubeless tire

Front tire

Size

130/70R18M/C 63H

Manufacturer/model

DUNLOP/D251F

Manufacturer/model

BRIDGESTONE/G851 RADIAL G

Rear tire

Size

190/60R17M/C 78H

Manufacturer/model

DUNLOP/D251

Manufacturer/model

BRIDGESTONE/G850 RADIAL G

Recommended lubricant

Engine oil or a suitable cable lu-
bricant

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CHASSIS

3-30

NOTE:

Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.

EAS21700

LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers.

EAS21710

LUBRICATING THE PEDAL

Lubricate the pivoting point and metal-to-metal
moving parts of the pedal.

EAS21720

LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal
moving parts of the sidestand.

EAS21740

LUBRICATING THE REAR SUSPENSION

Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.

NOTE:

Lubricate the pivoting points and contact surfac-
es between the connecting rod and frame and
between the swingarm and frame.

Recommended lubricant

Lithium-soap-based grease

Recommended lubricant

Lithium-soap-based grease

Recommended lubricant

Lithium-soap-based grease

Recommended lubricant

Lithium-soap-based grease

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ELECTRICAL SYSTEM

3-31

EAS21750

ELECTRICAL SYSTEM

EAS21760

CHECKING AND CHARGING THE BATTERY

Refer to “ELECTRICAL COMPONENTS” on
page 7-67.

EAS21770

CHECKING THE FUSES

Refer to “ELECTRICAL COMPONENTS” on
page 7-67.

EAS21790

REPLACING THE HEADLIGHT BULBS

1. Remove:

• Windshield (For XV19CTS(C)/

XV19CT(C)/XV19CTM(C))
Refer to “GENERAL CHASSIS” on page 4-1.

2. Remove:

• Headlight cover “1”

3. Disconnect:

• Air temperature sensor coupler “1”

4. Remove:

• Headlight assembly “1”

5. Replace:

• Low beam headlight bulb

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a. Disconnect:

• Headlight coupler “1”

b. Remove:

• Headlight bulb “2”

WARNING

EWA13320

Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.

c. Install:

• Headlight bulb

Secure the new headlight bulb with the head-
light bulb holder.

CAUTION:

ECA13690

Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.

d. Connect:

• Headlight coupler

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6. Replace:

• High beam headlight bulb

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a. Remove:

• Headlight bulb cover “1”

New

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ELECTRICAL SYSTEM

3-32

b. Disconnect:

• Headlight coupler “1”

c. Detach:

• Headlight bulb holder “2”

d. Remove:

• Headlight bulb

WARNING

EWA13320

Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.

e. Install:

• Headlight bulb

Secure the new headlight bulb with the head-
light bulb holder.

CAUTION:

ECA13690

f. Attach:

• Headlight bulb holder

g. Connect:

• Headlight coupler

h. Install:

• Headlight bulb cover

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7. Install:

• Headlight assembly

8. Connect:

• Air temperature sensor coupler

9. Install:

• Headlight cover

10.Install:

• Windshield (For XV19CTS(C)/

XV19CT(C)/XV19CTM(C))
Refer to “GENERAL CHASSIS” on page 4-1.

EAS21810

ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:

• Headlight beam (vertically)

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a. Turn the adjusting bolt “1” in direction “a” or

“b”.

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2. Adjust:

• Headlight beam (horizontally)

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a. Turn the adjusting bolt “1” in direction “a” or

“b”.

New

Headlight cover bolt

7 Nm (0.7 m·kg, 5.1 ft·lb)

Direction “a”

Headlight beam is raised.

Direction “b”

Headlight beam is lowered.

Direction “a”

Headlight beam moves to the right.

Direction “b”

Headlight beam moves to the left.

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CHASSIS

GENERAL CHASSIS

...................................................................................... 4-1

REMOVING THE WINDSHIELD ............................................................... 4-2
ASSEMBLING THE WINDSHIELD ........................................................... 4-2
INSTALLING THE WINDSHIELD.............................................................. 4-2
REMOVING THE BACKREST .................................................................. 4-5
ASSEMBLING THE BACKREST .............................................................. 4-5
INSTALLING THE BACKREST................................................................. 4-5
CHECKING THE SIDEBAG BRACKET SPRING NUTS........................... 4-8

FRONT WHEEL

............................................................................................ 4-15

REMOVING THE FRONT WHEEL ......................................................... 4-18
DISASSEMBLING THE FRONT WHEEL................................................ 4-18
CHECKING THE FRONT WHEEL .......................................................... 4-18
ASSEMBLING THE FRONT WHEEL...................................................... 4-19
ADJUSTING THE FRONT WHEEL STATIC BALANCE ......................... 4-19
INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) ............... 4-20

REAR WHEEL

............................................................................................... 4-23

REMOVING THE REAR WHEEL (DISC)................................................ 4-28
DISASSEMBLING THE REAR WHEEL .................................................. 4-28
CHECKING THE REAR WHEEL ............................................................ 4-28
CHECKING THE REAR BRAKE CALIPER BRACKET........................... 4-28
CHECKING THE REAR WHEEL DRIVE HUB........................................ 4-29
CHECKING AND REPLACING THE REAR WHEEL PULLEY ............... 4-29
ASSEMBLING THE REAR WHEEL ........................................................ 4-29
ADJUSTING THE REAR WHEEL STATIC BALANCE ........................... 4-29
INSTALLING THE REAR WHEEL (DISC) .............................................. 4-29

FRONT BRAKE

............................................................................................. 4-31

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REAR BRAKE

............................................................................................... 4-43

HANDLEBAR

................................................................................................ 4-55

REMOVING THE HANDLEBAR.............................................................. 4-57
CHECKING THE HANDLEBAR .............................................................. 4-57
INSTALLING THE HANDLEBAR ............................................................ 4-57

FRONT FORK

............................................................................................... 4-60

REMOVING THE FRONT FORK LEGS.................................................. 4-64
DISASSEMBLING THE FRONT FORK LEGS........................................ 4-64
CHECKING THE FRONT FORK LEGS .................................................. 4-65
ASSEMBLING THE FRONT FORK LEGS.............................................. 4-65
INSTALLING THE FRONT FORK LEGS ................................................ 4-68

STEERING HEAD

......................................................................................... 4-69

REMOVING THE LOWER BRACKET .................................................... 4-71
CHECKING THE STEERING HEAD....................................................... 4-71
INSTALLING THE STEERING HEAD..................................................... 4-71

REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM

...................... 4-73

HANDLING THE REAR SHOCK ABSORBER........................................ 4-76
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-76
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY AND

SWINGARM ........................................................................................... 4-76

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-77
CHECKING THE CONNECTING ARM AND RELAY ARM..................... 4-77
CHECKING THE SWINGARM ................................................................ 4-77
INSTALLING THE RELAY ARM, REAR SHOCK ABSORBER

ASSEMBLY AND CONNECTING ARMS............................................... 4-77

INSTALLING THE SWINGARM .............................................................. 4-79

BELT DRIVE

................................................................................................. 4-80

REMOVING THE DRIVE BELT AND DRIVE PULLEY ........................... 4-82
CHECKING THE DRIVE BELT ............................................................... 4-82
INSTALLING THE DRIVE BELT AND DRIVE PULLEY.......................... 4-82

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GENERAL CHASSIS

4-1

EAS21830

GENERAL CHASSIS

Removing the windshield (For XV19CTS(C)/XV19CT(C)/XV19CTM(C))

Order

Job/Parts to remove

Q’ty

Remarks

Windshield

Windshield bracket brace

Windshield bracket (left and right)

Windshield brace (left and right)

Windshield screen

Windshield holder bracket assembly (left and
right)

For installation, reverse the removal proce-
dure.

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

8 Nm (0.8 m

•

kg, 5.8 ft

•

Ib)

12 Nm (1.2 m

•

kg, 8.7 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

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GENERAL CHASSIS

4-2

ET1D71039

REMOVING THE WINDSHIELD

1. Remove:

• Windshield

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a. Insert the key “1” into the windshield lock, turn

it clockwise and then remove the key.

b. Remove the windshield by pushing it forward,

and then pulling it upward as shown.

WARNING

EW1D71016

Be careful not to push the vehicle forward
when removing the windshield. The vehicle
could fall off the sidestand.

CAUTION:

EC1D71025

Securely hold the windshield to prevent it
from falling when removing.

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ET1D71045

ASSEMBLING THE WINDSHIELD

1. Install:

• Windshield lock “1”

NOTE:

Align the projection “a” on the lock “1” with the
slot “b” in the windshield bracket “2”.

ET1D71040

INSTALLING THE WINDSHIELD

1. Install:

• Right windshield holder bracket assembly “1”

NOTE:

Pass the throttle cables “2” between the front
fork and the right windshield holder bracket as-
sembly.

2. Install:

• Windshield

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a. Fit the slot “a” in each windshield bracket (left

and right side) into its holder “b”.

NOTE:

Make sure that the throttle cables “1” are not
pinched.

b. Push the windshield backward until it snaps

into place.

2. Unlock.

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GENERAL CHASSIS

4-4

Removing the sidebags and backrest (For XV19CTS(C)/XV19CT(C)/XV19CTM(C))

Order

Job/Parts to remove

Q’ty

Remarks

Sidebag (left and right)

NOTE:

Water can be harmful to untreated leather.
Use Yamaha Saddle Soap or another quality
brand according to the manufacturer’s direc-
tions to clean the leather on the sidebags.
Polish the dry leather with a soft cloth, and
then treat with Yamaha Mink Oil or another
high-quality leather protectant for increased
water resistance.

Backrest assembly

Backrest upper bracket stay

Backrest pad

Backrest plate

Backrest upper bracket

Backrest lower bracket (left and right)

For installation, reverse the removal proce-
dure.

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

23 Nm (2.3 m

•

kg, 17 ft

•

Ib)

12 Nm (1.2 m

•

kg, 8.7 ft

•

Ib)

10 Nm (1.0 m

•

kg, 7.2 ft

•

Ib)

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GENERAL CHASSIS

4-5

ET1D71041

REMOVING THE BACKREST

1. Remove:

• Backrest

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a. Open the sidebag lids.
b. Insert the key “1” into the backrest lock, turn

it counterclockwise, and then remove the
key.

c. Pull the lever “1” on each side of the backrest

upward.

d. While holding the levers in the upward posi-

tion, lift the backrest upward and remove it by
pulling it to the rear.

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ET1D71046

ASSEMBLING THE BACKREST

1. Install:

• Backrest lock “1”

NOTE:

Align the projection “a” on the lock “1” with the
slot “b” in the left backrest lower bracket “2”.

2. Install:

• Backrest lower brackets “1”
• Backrest upper bracket “2”
• Backrest plate

NOTE:

Before tightening the bolts “3” to specification,
temporarily install the backrest lower brackets
on the backrest holders, making sure not to push
down on the rear of the brackets. The lower bolts
cannot be tightened when the backrest lower
brackets are installed completely.

ET1D71042

INSTALLING THE BACKREST

1. Install:

• Backrest

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▼

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▼

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▼

▼▼▼

a. Fit the slot “a” on each backrest bracket (left

and right side) into the groove of its holder “b”.

CAUTION:

EC1D71026

Be careful not to scratch the rear fender
when fitting the slot into the groove.

2. Unlock.

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Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 8