Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 9

 

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Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 9

 

 

GENERAL CHASSIS

4-6

b. Push the rear of the backrest down smoothly 

but forcefully to lock it in place and make sure 
that the lever hook “1” on each side is secure-
ly fit over its holder “2”.

WARNING

EW1D71017

Both lever hooks must be securely fitted 
over their holder. If the backrest is loose, a 
passenger might lose balance and fall.

c. Insert the key into the backrest lock, turn it 

clockwise, and then remove the key.

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▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

b

a

1

2

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GENERAL CHASSIS

4-7

Removing the sidebag brackets (For XV19CTS(C)/XV19CT(C)/XV19CTM(C))

Order

Job/Parts to remove

Q’ty

Remarks

Sidebag/Backrest

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

1

Passenger footrest (left and right)

2

2

Sidebag bracket brace

1

3

Sidebag bracket (left and right)

2

NOTE:

Remove only one sidebag bracket at a time. 
If both brackets are removed at the same 
time, the rear fender will fall.

4

O

2

 sensor lead guide

1

NOTE:

Pass the O

2

 sensor lead through the guide.

For installation, reverse the removal proce-
dure.

4

 

R

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

T

 

R

48 Nm (4.8 m 

•

 

kg, 35 ft

 

•

 

Ib)

LT

LT

1

1

3

3

2

4

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

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

GENERAL CHASSIS

4-8

ET1D71047

CHECKING THE SIDEBAG BRACKET 
SPRING NUTS

1. Check:

• Sidebag bracket spring nut height “a”

Out of specification 

→

 Adjust.

2. Check:

• Sidebag bracket spring nuts

Damage 

→

 Replace.

 

Sidebag bracket spring nut 
height

12.0 mm (0.47 in)

a

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

GENERAL CHASSIS

4-9

Removing the seats and side covers

Order

Job/Parts to remove

Q’ty

Remarks

1

Rider seat

1

2

Passenger seat

1

3

Tool kit

1

4

Tool kit tray

1

5

Rider seat bracket assembly

1

6

Right side cover

1

7

Left side cover

1

8

Seat lock cable assembly

1

For installation, reverse the removal proce-
dure.

1

6

2

4

5

7

8

3

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

T

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

LT

LT

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

LT

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

GENERAL CHASSIS

4-10

Removing the headlight

Order

Job/Parts to remove

Q’ty

Remarks

1

Headlight cover

1

2

Air temperature sensor coupler

1

Disconnect.

3

Air temperature sensor

1

4

Headlight (low beam) coupler

1

Disconnect.

5

Headlight (high beam) coupler

1

Disconnect.

6

Headlight lens unit

1

7

Front left turn signal/position light coupler

1

Disconnect.

8

Front right turn signal/position light coupler

1

Disconnect.

9

Wire harness stopper bracket

1

10

Left handlebar switch coupler

4

Disconnect.

11

Right handlebar switch coupler

3

Disconnect.

12

Main switch coupler

2

Disconnect.

13

Headlight body

1

For installation, reverse the removal proce-
dure.

1

3

2

8

7

10

10

9

4

11

12

5

6

13

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

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

GENERAL CHASSIS

4-11

Removing the battery

Order

Job/Parts to remove

Q’ty

Remarks

Tool kit tray/Seat bracket

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

1

ECU band

1

2

ECU (electronic control unit)

1

3

Coupler tray

1

4

Negative terminal cover

1

5

Negative battery lead

1

Disconnect.

6

Positive battery lead

1

Disconnect.

7

Battery

1

8

Battery band

1

9

Sub-wire harness 1

1

Disconnect.

10

Main fuse

1

11

Plastic locking tie

1

12

Fuse box

1

13

Starter relay coupler

1

Disconnect.

14

Starter relay

1

15

Diode 1

1

16

Relay unit

1

13

18

17

16

15

19

14

12

19

20

8

5

6

7

2

1

3

9

10

(3)

11

4

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

GENERAL CHASSIS

4-12

17

Headlight relay

1

18

Turn signal relay

1

19

Plastic locking tie

2

20

Battery box

1

For installation, reverse the removal proce-
dure.

Removing the battery

Order

Job/Parts to remove

Q’ty

Remarks

13

18

17

16

15

19

14

12

19

20

8

5

6

7

2

1

3

9

10

(3)

11

4

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GENERAL CHASSIS

4-13

Removing the air filter case

Order

Job/Parts to remove

Q’ty

Remarks

Rider seat

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

Fuel tank

Refer to “FUEL TANK” on page 6-1.

Pressure regulator cover

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

1

Air filter case cover

1

2

Air filter element

1

3

Cylinder-#1 intake air pressure sensor coupler

1

Disconnect.

4

Cylinder-#1 intake air pressure sensor hose

1

Disconnect.

5

Cylinder-#1 intake air pressure sensor

1

6

Cylinder-#1 intake air pressure sensor bracket

1

7

Cylinder-#2 intake air pressure sensor coupler

1

Disconnect.

8

Cylinder-#2 intake air pressure sensor hose

1

Disconnect.

9

Cylinder-#2 intake air pressure sensor

1

10

Cylinder-#2 intake air pressure sensor bracket

1

11

Cylinder head breather hose

1

Disconnect.

12

Air filter case breather hose 1

1

Disconnect.

13

Air filter case breather hose 2

1

Disconnect.

14

ISC (idle speed control) unit inlet hose

1

Disconnect.

15

9

7

8

14

16

11

4

3

12

13

16

5

6

1

17

2

10

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

 

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

(7)

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

GENERAL CHASSIS

4-14

15

Air filter case bracket

1

16

Air filter case joint clamp screw

2

Loosen.

17

Air filter case

1

For installation, reverse the removal proce-
dure.

Removing the air filter case

Order

Job/Parts to remove

Q’ty

Remarks

15

9

7

8

14

16

11

4

3

12

13

16

5

6

1

17

2

10

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

 

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

(7)

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FRONT WHEEL

4-15

EAS21870

FRONT WHEEL

Removing the front wheel and brake discs

Order

Job/Parts to remove

Q’ty

Remarks

NOTE:

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

1

Right front fender stay

1

2

Left front fender stay

1

3

Front fender stay rod

1

4

Front brake hose guide

2

5

Right front brake hose guide bracket

1

6

Left front brake hose guide bracket

1

7

Front fender

1

8

Reflector

2

9

Reflector bracket

2

10

Front brake caliper

2

11

Front wheel axle pinch bolt

1

Loosen.

12

Front wheel axle

1

13

Front wheel

1

T

 

R

7 Nm (0.7 m

 

•

 

kg, 5.1 ft

 

•

 

Ib)

T

 

R

7 Nm (0.7 m

 

•

 

kg, 5.1 ft

 

•

 

Ib)

T

 

R

7 Nm (0.7 m

 

•

 

kg, 5.1 ft

 

•

 

Ib)

LT

LT

LT

LT

LT

LT

LT

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

T

 

R

72 Nm (7.2 m 

•

 

kg, 52 ft

 

•

 

Ib)

4

9

10

(4)

4

10

2

9

11

8

8

1

3

12

7

5

6

(6)

(6)

14

14

15

16

13

16

LT

LT

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

FRONT WHEEL

4-16

14

Collar

2

15

Front brake disc cover

1

16

Front brake disc

2

For installation, reverse the removal proce-
dure.

Removing the front wheel and brake discs

Order

Job/Parts to remove

Q’ty

Remarks

T

 

R

7 Nm (0.7 m

 

•

 

kg, 5.1 ft

 

•

 

Ib)

T

 

R

7 Nm (0.7 m

 

•

 

kg, 5.1 ft

 

•

 

Ib)

T

 

R

7 Nm (0.7 m

 

•

 

kg, 5.1 ft

 

•

 

Ib)

LT

LT

LT

LT

LT

LT

LT

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

T

 

R

72 Nm (7.2 m 

•

 

kg, 52 ft

 

•

 

Ib)

4

9

10

(4)

4

10

2

9

11

8

8

1

3

12

7

5

6

(6)

(6)

14

14

15

16

13

16

LT

LT

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

FRONT WHEEL

4-17

Disassembling the front wheel

Order

Job/Parts to remove

Q’ty

Remarks

1

Oil seal

2

2

Wheel bearing

2

3

Spacer

1

For assembly, reverse the disassembly pro-
cedure.

2

1

2

1

3

LS

LS

New

New

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

FRONT WHEEL

4-18

EAS21900

REMOVING THE FRONT WHEEL

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. Remove:

• Right front fender stay “1”
• Left front fender stay “2”
• Front fender stay rod “3”

NOTE:

• Remove the right front fender stay bolts and 

left front fender stay bolt (rear side), then hold 
the rod with a wrench “4” and remove the left 
front fender stay bolt (front side) “5”.

• Remove the rod from the right side of the vehi-

cle.

3. Loosen:

• Front wheel axle pinch bolt “1”

4. Remove:

• Front brake calipers

NOTE:

Do not apply the brake lever when removing the 
brake calipers.

5. Elevate:

• Front wheel

NOTE:

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

EAS21910

DISASSEMBLING THE FRONT WHEEL

1. Remove:

• Oil seals
• Wheel bearings

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Clean the outside of the front wheel hub.
b. Remove the oil seals “1” with a flathead 

screwdriver.

NOTE:

To prevent damaging the wheel, place a rag “2” 
between the screwdriver and the wheel surface.

c. Remove the wheel bearings “3” with a gener-

al bearing puller.

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▲

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EAS21920

CHECKING THE FRONT WHEEL

1. Check:

• Front wheel axle

Roll the wheel axle on a flat surface.
Bends 

→

 Replace.

WARNING

EWA13460

Do not attempt to straighten a bent wheel ax-
le.

1

2

3

5

4

1

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

FRONT WHEEL

4-19

2. Check:

• Tire
• Front wheel

Damage/wear 

→

 Replace.

Refer to “CHECKING THE TIRES” on page 
3-27 and “CHECKING THE WHEELS” on 
page 3-29.

3. Measure:

• Radial wheel runout “1”
• Lateral wheel runout “2”

Over the specified limits 

→

 Replace.

4. Check:

• Wheel bearings

Front wheel turns roughly or is loose 

→

 Re-

place the wheel bearings.

• Oil seals

Damage/wear 

→

 Replace.

EAS21960

ASSEMBLING THE FRONT WHEEL

1. Install:

• Wheel bearings 

• Oil seals 

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Install the new wheel bearings and oil seals in 

the reverse order of disassembly.

CAUTION:

EC1D71011

Do not contact the wheel bearing inner race 
“1” or balls “2”. Contact should be made 
only with the outer race “3”.

NOTE:

Use a socket “4” that matches the diameter of 
the wheel bearing outer race and oil seal.

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▲

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▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

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EAS21970

ADJUSTING THE FRONT WHEEL STATIC 
BALANCE

NOTE:

• After replacing the tire, wheel or both, the front 

wheel static balance should be adjusted.

• Adjust the front wheel static balance with the 

brake disc installed.

1. Remove:

• Balancing weight(s)

2. Find:

• Front wheel’s heavy spot

NOTE:

Place the front wheel on a suitable balancing 
stand.

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Spin the front wheel.
b. When the front wheel stops, put an “X

1

” mark 

at the bottom of the wheel.

 

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

0.5 mm (0.02 in)

New

New

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

FRONT WHEEL

4-20

c. Turn the front wheel 90

°

 so that the “X

1

” mark 

is positioned as shown.

d. Release the front wheel.
e. When the wheel stops, put an “X

2

” mark at 

the bottom of the wheel.

f. Repeat steps (d) through (f) several times un-

til all the marks come to rest at the same spot.

g. The spot where all the marks come to rest is 

the front wheel’s heavy spot “X”.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

3. Adjust:

• Front wheel static balance

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Install a balancing weight “1” onto the rim ex-

actly opposite the heavy spot “X”.

NOTE:

Start with the lightest weight.

b. Turn the front wheel 90° so that the heavy 

spot is positioned as shown.

c. If the heavy spot does not stay in that posi-

tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheel 

is balanced.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

4. Check:

• Front wheel static balance

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Turn the front wheel and make sure it stays at 

each position shown.

b. If the front wheel does not remain stationary 

at all of the positions, rebalance it.

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▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

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▲ ▲▲▲

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▲

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EAS22000

INSTALLING THE FRONT WHEEL (FRONT 
BRAKE DISCS)

The following procedure applies to both of the 
front brake discs.
1. Install:

• Front brake disc
• Front brake disc cover

NOTE:

Tighten the front brake disc bolts in stages and 
in a crisscross pattern.

T

 

R

.

 

Front brake disc bolt

23 Nm (2.3 m·kg, 17 ft·lb)
LOCTITE

®

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

FRONT WHEEL

4-21

2. Check:

• Front brake discs

Refer to “CHECKING THE FRONT BRAKE 
DISCS” on page 4-36.

3. Lubricate:

• Oil seal lips

4. Install:

• Front wheel axle

NOTE:

Install the tire and wheel with the mark “1” point-
ing in the direction of wheel rotation.

5. Tighten:

• Front wheel axle
• Front wheel axle pinch bolt

CAUTION:

EC1D71004

Before tightening the wheel axle, push down 
hard on the handlebar several times and 
check if the front fork rebounds smoothly.

6. Install:

• Front brake calipers

WARNING

EWA13500

Make sure the brake hose is routed properly.

7. Install:

• Front fender
• Left front brake hose guide bracket
• Right front brake hose guide bracket

NOTE:

• Temporarily tighten the front fender bolts.

• Apply locking agent (LOCTITE

®

) to the threads 

of the front fender bolts.

8. Install:

• Front fender stay rod “1”
• Left front fender stay “2”
• Right front fender stay “3”

NOTE:

• Insert the rod into the front wheel axle from the 

right side of the vehicle.

• Tighten the left front fender stay bolt (front 

side) “4” to specification while holding the rod 
with a wrench “5”, and then tighten the left front 
fender stay bolt (rear side) and right front fend-
er stay bolts to specification.

9. Tighten:

• Front fender bolts

 

Recommended lubricant

Lithium-soap-based grease

T

 

R

.

 

Front wheel axle

72 Nm (7.2 m·kg, 52 ft·lb)

Front wheel axle pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb)

T

 

R

.

 

Front brake caliper bolt

40 Nm (4.0 m·kg, 29 ft·lb)

T

 

R

.

 

Front fender bolt

16 Nm (1.6 m·kg, 11 ft·lb)
LOCTITE

®

3

2

1

4

5

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