Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 10

FRONT WHEEL

4-22

REAR WHEEL

4-23

EAS22020

REAR WHEEL

Removing the rear fender

Order

Job/Parts to remove

Q’ty

Remarks

Rider seat/Passenger seat/Tool kit tray

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

1

Sub-wire harness 1 coupler

1

Disconnect.

2

Rear fender bracket

2

3

Dowel pin

4

4

Rear fender assembly

1

For installation, reverse the removal proce-
dure.

3

1

3

3

3

4

2

2

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

LT

LT

REAR WHEEL

4-24

Removing the rear wheel

Order

Job/Parts to remove

Q’ty

Remarks

NOTE:

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

Muffler

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

1

Upper drive belt cover

1

2

Rear brake caliper

1

3

Rear brake pad

2

4

Brake pad spring

2

5

Drive belt adjusting locknut

2

Loosen.

6

Drive belt adjusting bolt

2

Loosen.

7

Rear wheel axle nut

1

8

Washer

1

9

Rear wheel axle

1

10

Right drive belt puller

1

11

Left drive belt puller

1

12

Rear brake caliper bracket

1

13

Collar

1

Black

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

27 Nm (2.7 m 

•

 

kg, 19 ft

 

•

 

Ib)

T

 

R

150 Nm (15.0 m 

•

 kg, 110 ft 

•

 lb)

12

9

4

2

4

3

13

15

7

8

6

5

10

14

6

5

11

1

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

LS

LS

LS

REAR WHEEL

4-25

14

Collar

1

Silver

15

Rear wheel

1

For installation, reverse the removal proce-
dure.

Removing the rear wheel

Order

Job/Parts to remove

Q’ty

Remarks

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

27 Nm (2.7 m 

•

 

kg, 19 ft

 

•

 

Ib)

T

 

R

150 Nm (15.0 m 

•

 kg, 110 ft 

•

 lb)

12

9

4

2

4

3

13

15

7

8

6

5

10

14

6

5

11

1

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

LS

LS

LS

REAR WHEEL

4-26

Removing the rear brake disc and rear wheel drive hub

Order

Job/Parts to remove

Q’ty

Remarks

1

Rear brake disc cover

1

2

Rear brake disc

1

3

Rear wheel pulley

1

4

Oil seal

1

5

Circlip

1

6

Rear wheel drive hub

1

7

Circlip

1

8

Bearing

1

9

Collar

1

10

Bearing

1

11

Rear wheel drive hub damper

6

12

Rear wheel

1

For installation, reverse the removal proce-
dure.

REAR WHEEL

4-27

Disassembling the rear wheel

Order

Job/Parts to remove

Q’ty

Remarks

1

Collar

1

2

Bearing

1

3

Spacer

1

4

Oil seal

1

5

Circlip

1

6

Bearing

1

For assembly, reverse the disassembly pro-
cedure.

6

4

3

2

1

New

LS

5

REAR WHEEL

4-28

EAS28760

REMOVING THE REAR WHEEL (DISC)

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 a suitable stand so that the 
rear wheel is elevated.

2. Remove:

• Rear brake caliper “1”

NOTE:

Do not depress the brake pedal when removing 
the brake caliper.

3. Loosen:

• Drive belt adjusting locknuts “1”
• Drive belt adjusting bolts “2”

4. Remove:

• Rear wheel axle nut “1”
• Rear wheel axle “2”
• Rear wheel

NOTE:

Push the rear wheel forward and remove the 
drive belt from the rear wheel pulley.

EAS22080

DISASSEMBLING THE REAR WHEEL

1. Remove:

• Oil seals
• Wheel bearings

Refer to “DISASSEMBLING THE FRONT 
WHEEL” on page 4-18.

EAS22090

CHECKING THE REAR WHEEL

1. Check:

• Rear wheel axle
• Rear wheel
• Wheel bearings
• Oil seals

Refer to “CHECKING THE FRONT WHEEL” 
on page 4-18.

2. Check:

• Tire
• Rear 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
• Lateral wheel runout

Refer to “CHECKING THE FRONT WHEEL” 
on page 4-18.

ET1D71024

CHECKING THE REAR BRAKE CALIPER 
BRACKET

1. Check:

• Rear brake caliper bracket

Cracks/damage 

→

 Replace.

1

2

1

 

Radial wheel runout limit

1.0 mm (0.04 in)

Lateral wheel runout limit

0.5 mm (0.02 in)

1

2

REAR WHEEL

4-29

EAS22110

CHECKING THE REAR WHEEL DRIVE HUB

1. Check:

• Rear wheel drive hub

Cracks/damage 

→

 Replace.

• Rear wheel drive hub dampers

Damage/wear 

→

 Replace.

EAS22130

CHECKING AND REPLACING THE REAR 
WHEEL PULLEY

1. Check:

• Rear wheel pulley

Surface plating has come off 

→

 Replace the 

rear wheel pulley.
Bent teeth 

→

 Replace the rear wheel pulley.

2. Replace:

• Rear wheel pulley

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▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Remove the self-locking nuts and the rear 

wheel pulley.

b. Clean the rear wheel drive hub with a clean 

cloth, especially the surfaces that contact the 
pulley.

c. Install the new rear wheel pulley.

NOTE:

Tighten the self-locking nuts in stages and in a 
crisscross pattern.

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▲

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▲ ▲▲▲

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EAS22140

ASSEMBLING THE REAR WHEEL

1. Install:

• Wheel bearings 

• Oil seals 

Refer to “ASSEMBLING THE FRONT 
WHEEL” on page 4-19.

EAS22150

ADJUSTING THE REAR WHEEL STATIC 
BALANCE

NOTE:

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

wheel static balance should be adjusted.

• Adjust the rear wheel static balance with the 

brake disc and rear wheel drive hub installed.

1. Adjust:

• Rear wheel static balance

Refer to “ADJUSTING THE FRONT WHEEL 
STATIC BALANCE” on page 4-19.

EAS28770

INSTALLING THE REAR WHEEL (DISC)

1. Lubricate:

• Rear wheel axle
• Oil seal lips

2. Install:

• Rear brake disc
• Rear brake disc cover

NOTE:

• Apply locking agent (LOCTITE

®

) to the threads 

of the brake disc bolts.

• Tighten the brake disc bolts in stages and in a 

crisscross pattern.

3. Check:

• Rear brake disc

Refer to “CHECKING THE REAR BRAKE 
DISC” on page 4-49.

4. Install:

• Rear wheel axle
• Washer
• Rear wheel axle nut

T

 

R

.

 

Rear wheel pulley self-locking 
nut

95 Nm (9.5 m·kg, 68 ft·lb)

New

New

 

Recommended lubricant

Lithium-soap-based grease

T

 

R

.

 

Rear brake disc bolt

18 Nm (1.8 m·kg, 13 ft·lb)
LOCTITE

®

LT

REAR WHEEL

4-30

NOTE:

Temporarily tighten the wheel axle nut.

5. Adjust:

• Drive belt slack

Refer to “ADJUSTING THE DRIVE BELT 
SLACK” on page 3-24.

6. Tighten:

• Rear wheel axle nut

7. Install:

• Rear brake caliper

WARNING

EWA13500

Make sure the brake hose is routed properly.

T

 

R

.

 

Rear wheel axle nut

150 Nm (15.0 m·kg, 110 ft·lb)

T

 

R

.

 

Rear brake caliper

27 Nm (2.7 m·kg, 19 ft·lb)

FRONT BRAKE

4-31

EAS22210

FRONT BRAKE

Removing the front brake pads

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of 
the front brake calipers.

1

Brake hose holder

1

2

Reflector

1

3

Reflector bracket

1

4

Front brake caliper

1

5

Brake pad clip

2

6

Brake pad pin

1

7

Brake pad spring

1

8

Brake pad

2

9

Brake pad shim

2

For installation, reverse the removal proce-
dure.

T

 

R

40 Nm (4.0 m

 

•

 

kg, 29 ft

 

•

 

Ib)

T

 

R

6 Nm (0.6 m

 

•

 

kg, 4.3 ft

 

•

 

Ib)

LT

T

 

R

10 Nm (1.0 m

 

•

 

kg, 7.2 ft

 

•

 

Ib)

1

4

8

5

3

2

9

7

9

6

FRONT BRAKE

4-32

Removing the front brake master cylinder

Order

Job/Parts to remove

Q’ty

Remarks

Brake fluid

Drain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-22.

1

Right rearview mirror

1

2

Brake master cylinder reservoir cap

1

3

Brake master cylinder reservoir diaphragm hold-
er

1

4

Brake master cylinder reservoir diaphragm

1

5

Brake  lever

1

6

Brake light switch connector

2

Disconnect.

7

Brake light switch

1

8

Front brake hose union bolt

1

9

Copper washer

2

10

Front brake hose

1

11

Front brake master cylinder holder

1

12

Front brake master cylinder

1

For installation, reverse the removal proce-
dure.

 

R

30 Nm (3.0 m 

•

 

kg, 22 ft

 

•

 

Ib)

LS

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

New

2

1

3

4

12

5

6

10

7

9

9

8

11

FRONT BRAKE

4-33

Disassembling the front brake master cylinder

Order

Job/Parts to remove

Q’ty

Remarks

1

Dust boot

1

2

Circlip

1

3

Brake master cylinder kit

1

4

Brake master cylinder body

1

For assembly, reverse the disassembly pro-
cedure.

New

1

3

2

4

LS

New

FRONT BRAKE

4-34

Removing the front brake calipers

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of 
the front brake calipers.

Brake fluid

Drain.
Refer to “BLEEDING THE HYDRAULIC 
BRAKE SYSTEM” on page 3-22.

1

Brake hose holder

1

2

Front brake hose union bolt

1

3

Copper washer

2

4

Front brake hose

1

5

Reflector

1

6

Reflector bracket

1

7

Front brake caliper

1

For installation, reverse the removal proce-
dure.

R

40 Nm (4.0 m

 

•

 

kg, 29 ft

 

•

 

Ib)

R

10 Nm (1.0 m

 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

7

3

6

5

New

3

New

4

2

1

T

 

R

32 Nm (3.2 m 

•

 

kg, 23 ft

 

•

 

Ib)

FRONT BRAKE

4-35

Disassembling the front brake calipers

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of 
the front brake calipers.

1

Brake pad clip

2

2

Brake pad pin

1

3

Brake pad spring

1

4

Brake pad

2

5

Brake pad shim

2

6

Brake caliper piston

4

7

Brake caliper piston seal

8

8

Bleed screw

1

For assembly, reverse the disassembly pro-
cedure.

FRONT BRAKE

4-36

EAS22220

INTRODUCTION

WARNING

EWA14100

Disc brake components rarely require disas-
sembly. Therefore, always follow these pre-
ventive measures:
• Never disassemble brake components un-

less absolutely necessary.

• If any connection on the hydraulic brake 

system is disconnected, the entire brake 
system must be disassembled, drained, 
cleaned, properly filled, and bled after reas-
sembly.

• Never use solvents on internal brake com-

ponents.

• Use only clean or new brake fluid for clean-

ing brake components.

• Brake fluid may damage painted surfaces 

and plastic parts. Therefore, always clean 
up any spilt brake fluid immediately.

• Avoid brake fluid coming into contact with 

the eyes as it can cause serious injury.

• FIRST AID FOR BRAKE FLUID ENTERING 

THE EYES:

• Flush with water for 15 minutes and get im-

mediate medical attention.

EAS22240

CHECKING THE FRONT BRAKE DISCS

The following procedure applies to both brake 
discs.
1. Remove:

• Front wheel

Refer to “FRONT WHEEL” on page 4-15.

2. Check:

• Brake disc

Damage/galling 

→

 Replace.

3. Measure:

• Brake disc deflection

Out of specification 

→

 Correct the brake disc 

deflection or replace the brake disc.

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▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Place the vehicle on a suitable stand so that 

the front wheel is elevated.

b. Before measuring the front brake disc deflec-

tion, turn the handlebar to the left or right to 
ensure that the front wheel is stationary.

c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against 

the brake disc surface.

e. Measure the deflection 1.5 mm (0.06 in) be-

low the edge of the brake disc.

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▲

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▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

4. Measure:

• Brake disc thickness

Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification 

→

 Replace.

5. Adjust:

• Brake disc deflection

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.

NOTE:

• Apply locking agent (LOCTITE

®

) to the threads 

of the brake disc bolts.

• Tighten the brake disc bolts in stages and in a 

crisscross pattern.

 

Brake disc deflection limit

0.10 mm (0.0039 in)

 

Brake disc thickness limit

4.5 mm (0.18 in)

T

 

R

.

 

Front brake disc bolt

23 Nm (2.3 m·kg, 17ft·lb)
LOCTITE

®

FRONT BRAKE

4-37

d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment 

steps until the brake disc deflection is within 
specification.

f. If the brake disc deflection cannot be brought 

within specification, replace the brake disc.

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▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

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6. Install:

• Front wheel

Refer to “FRONT WHEEL” on page 4-15.

EAS22270

REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake 
calipers.

NOTE:

When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disassem-
ble the brake caliper.

1. Measure:

• Brake pad wear limit “a”

Out of specification 

→

 Replace the brake 

pads as a set.

2. Install:

• Brake pad shims

(onto the brake pads)

• Brake pads
• Brake pad spring

NOTE:

Always install new brake pads, brake pad shims, 
and a brake pad spring as a set.

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▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

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

bleed screw “2”. Put the other end of the hose 
into an open container.

b. Loosen the bleed screw and push the brake 

caliper pistons into the brake caliper with your 
finger.

c. Tighten the bleed screw.

d. Install a new brake pad shim onto each new 

brake pad.

e. Install new brake pads and a new brake pad 

spring.

NOTE:

The arrow mark “a” on the brake pad spring 
must point in the direction of disc rotation.

 

Brake pad lining thickness (in-
ner)

5.5 mm (0.22 in)

Limit

0.5 mm (0.02 in)

Brake pad lining thickness (out-
er)

5.5 mm (0.22 in)

Limit

0.5 mm (0.02 in)

T

 

R

.

 

Bleed screw (front brake caliper)

6 Nm (0.6 m·kg, 4.3ft·lb)

a

2

1