Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 12

REAR BRAKE

4-54

5. Check:

• Brake pedal operation

Soft or spongy feeling 

→

 Bleed the brake sys-

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

6. Adjust:

• Brake pedal position

Refer to “ADJUSTING THE REAR DISC 
BRAKE” on page 3-20.

7. Adjust:

• Rear brake light operation timing

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

a

HANDLEBAR

4-55

EAS22840

HANDLEBAR

Removing the handlebar

Order

Job/Parts to remove

Q’ty

Remarks

Headlight body

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

1

Rearview mirror

2

2

Plastic clamp

2

3

Front brake light switch connector

2

Disconnect.

4

Front brake master cylinder holder

1

5

Front brake master cylinder assembly

1

6

Throttle cable holder

1

7

Right handlebar switch

1

8

Throttle cable

2

9

Grip end

2

10

Throttle grip

1

11

Clutch switch coupler

1

Disconnect.

12

Clutch master cylinder holder

1

13

Clutch master cylinder assembly

1

14

Left handlebar switch

2

1

5

13

18

14

17

15

12

14

11

7

9

4

7

8

19

2

2

3

16

9

1

6

10

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

28 Nm (2.8 m 

•

 

kg, 20 ft

 

•

 

Ib)

 

R

50 Nm (5.0 m 

•

 

kg, 36 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

32 Nm (3.2 m 

•

 

kg, 23 ft

 

•

 

Ib)

LS

LS

HANDLEBAR

4-56

15

Handlebar grip

1

16

Upper handlebar holder

1

17

Handlebar

1

18

Hose guide

1

19

Lower handlebar holder

1

For installation, reverse the removal proce-
dure.

Removing the handlebar

Order

Job/Parts to remove

Q’ty

Remarks

1

5

13

18

14

17

15

12

14

11

7

9

4

7

8

19

2

2

3

16

9

1

6

10

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

28 Nm (2.8 m 

•

 

kg, 20 ft

 

•

 

Ib)

 

R

50 Nm (5.0 m 

•

 

kg, 36 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

32 Nm (3.2 m 

•

 

kg, 23 ft

 

•

 

Ib)

LS

LS

HANDLEBAR

4-57

EAS22860

REMOVING THE HANDLEBAR

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:

• Handlebar grip “1”

NOTE:

Blow compressed air between the handlebar 
and the left handlebar grip, and gradually push 
the grip off the handlebar.

EAS22880

CHECKING THE HANDLEBAR

1. Check:

• Handlebar

Bends/cracks/damage 

→

 Replace.

WARNING

EWA13690

Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.

EAS22930

INSTALLING THE HANDLEBAR

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. Connect:

• Throttle cable (decelerator cable) “1”

(to the right handlebar switch “2”)

NOTE:

Rotate the right handlebar switch and screw it 
onto the end of the throttle cable.

3. Pass the left and right handlebar switch leads 

through the handlebar.

4. Install:

• Handlebar “1”
• Upper handlebar holder “2”

CAUTION:

ECA14250

• First, tighten the bolts on the front side of 

the handlebar holder, and then on the rear 
side.

• Turn the handlebar all the way to the left 

and right. If there is any contact with the 
fuel tank, adjust the handlebar position.

NOTE:

Align the match marks “a” on the handlebar with 
the upper surface of the lower handlebar hold-
ers.

5. Install:

• Handlebar grip

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Apply a thin coat of rubber adhesive onto the 

left end of the handlebar.

b. Slide the handlebar grip over the left end of 

the handlebar.

c. Wipe off any excess rubber adhesive with a 

clean rag.

T

 

R

.

 

Upper handlebar holder bolt

28 Nm (2.8 m·kg, 20 ft·lb)

2

1

2

1

a

HANDLEBAR

4-58

WARNING

EWA13700

Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

6. Install:

• Left handlebar switch “1”

NOTE:

Align the projection “a” on the left handlebar 
switch with the hole “b” in the handlebar.

7. Install:

• Clutch master cylinder “1”
• Clutch master cylinder holder “2”

NOTE:

• Align the end of the clutch master cylinder 

holder with the punch mark “a” on the handle-
bar.

• First tighten the rear bolt, then the front bolt.

8. Install:

• Throttle grip
• Throttle cables
• Right handlebar switch “1”
• Grip end “2”

NOTE:

•  Align the projection “a” on the right handlebar 

switch with the hole “b” in the handlebar.

• There should be 1–3 mm (0.04–0.12 in) of 

clearance “c” between the throttle grip and the 
grip end.

9. Install:

• Front brake master cylinder “1”
• Front brake master cylinder holder “2”

NOTE:

• Align the end of the front brake master cylinder 

holder with the punch mark “a” on the handle-
bar.

• First tighten the rear bolt, then the front bolt.

10.Adjust:

• Throttle cable free play

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

T

 

R

.

 

Clutch master cylinder holder 
bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

a

b

1

1

2

a

T

 

R

.

 

Front brake master cylinder hold-
er bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

1

a

b

2

c

a

2

1

HANDLEBAR

4-59

 

Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)

FRONT FORK

4-60

EAS22950

FRONT FORK

Removing the front fork legs

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of 
the front fork legs.

Windshield bracket (left and right)

For XV19CTS(C)/XV19CT(C)/
XV19CTM(C) only

Lower handlebar holder

Refer to “HANDLEBAR” on page 4-55.

Front fender

Refer to “FRONT WHEEL” on page 4-15.

1

Upper bracket cover

1

2

Upper bracket pinch bolt

4

Loosen.

3

Cap bolt

1

Loosen.

4

Steering stem nut

1

5

Upper bracket

1

6

Upper front fork cover

1

7

Upper front fork cover spacer

1

8

Upper front fork cover washer

1

9

Lower front fork cover nut

2

10

Lower bracket pinch bolt

2

Loosen.

11

Lower front fork cover

1

1

5

6

7

8

11

3

12

9

2

10

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

115 Nm (11.5 m 

•

 kg, 85 ft 

•

 lb)

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

 

R

19 Nm (1.9 m 

•

 

kg, 13 ft

 

•

 

Ib)

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

LT

4

LT

2

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

FRONT FORK

4-61

12

Front fork leg

1

For installation, reverse the removal proce-
dure.

Removing the front fork legs

Order

Job/Parts to remove

Q’ty

Remarks

1

5

6

7

8

11

3

12

9

2

10

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

115 Nm (11.5 m 

•

 kg, 85 ft 

•

 lb)

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

 

R

19 Nm (1.9 m 

•

 

kg, 13 ft

 

•

 

Ib)

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

LT

4

LT

2

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

FRONT FORK

4-62

Disassembling the front fork legs

Order

Job/Parts to remove

Q’ty

Remarks

The following procedure applies to both of 
the front fork legs.

1

Cap bolt

1

2

O-ring

1

3

Spacer

1

4

Spring seat

1

5

Fork spring

1

6

Dust seal

1

7

Oil seal clip

1

8

Damper rod bolt

1

9

Copper washer

1

10

Damper rod

1

11

Rebound spring

1

12

Inner tube

1

13

Oil seal

1

14

Washer

1

15

Outer tube bushing

1

16

Inner tube bushing

1

6

7

13

14

12

16

17

18

9

8

19

15

5

10

11

1

2

3

4

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

New

New

New

New

New

New

LT

New

FRONT FORK

4-63

17

Spring

1

18

Oil flow stopper

1

19

Outer tube

1

For assembly, reverse the disassembly pro-
cedure.

Disassembling the front fork legs

Order

Job/Parts to remove

Q’ty

Remarks

6

7

13

14

12

16

17

18

9

8

19

15

5

10

11

1

2

3

4

T

 

R

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

 

R

40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

New

New

New

New

New

New

LT

New

FRONT FORK

4-64

EAS22960

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the 
front fork legs.
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 
front wheel is elevated.

2. Loosen:

• Lower bracket pinch bolts

WARNING

EW1D71007

Before loosening the lower bracket pinch 
bolts, support the front fork leg.

EAS22980

DISASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the 
front fork legs.
1. Drain:

• Fork oil

NOTE:

Stroke the outer tube several times while drain-
ing the fork oil.

2. Remove:

• Dust seal “1”
• Oil seal clip “2”

(with a flathead screwdriver)

CAUTION:

ECA14180

Do not scratch the inner tube.

3. Remove:

• Damper rod bolt “1”
• Copper washer

NOTE:

While holding the damper rod with the damper 
rod holder “2” and T-handle “3”, loosen the 
damper rod bolt.

4. Remove:

• Inner tube

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a 

vise with soft jaws.

c. Separate the inner tube from the outer tube 

by pulling the inner tube forcefully but careful-
ly.

CAUTION:

ECA14190

• Excessive force will damage the oil seal 

and bushing. A damaged oil seal or bush-
ing must be replaced.

• Avoid bottoming the inner tube into the out-

er tube during the above procedure, as the 
oil flow stopper will be damaged.

 

Damper rod holder

90890-01460

T-handle

90890-01326

T-handle 3/8" drive 60 cm long

YM-01326

FRONT FORK

4-65

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

EAS23010

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the 
front fork legs.
1. Check:

• Inner tube
• Outer tube

Bends/damage/scratches 

→

 Replace.

WARNING

EWA13650

Do not attempt to straighten a bent inner 
tube as this may dangerously weaken it.

2. Measure:

• Spring free length “a”

Out of specification 

→

 Replace.

3. Check:

• Damper rod

Damage/wear 

→

 Replace.

Obstruction 

→

 Blow out all of the oil passag-

es with compressed air.

• Oil flow stopper

Damage 

→

 Replace.

CAUTION:

ECA14200

• The front fork leg has a built-in damper ad-

justing rod and a very sophisticated inter-
nal construction, which are particularly 
sensitive to foreign material.

• When disassembling and assembling the 

front fork leg, do not allow any foreign ma-
terial to enter the front fork.

4. Check:

• Cap bolt O-ring

Damage/wear 

→

 Replace.

EAS23020

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the 
front fork legs.

WARNING

EWA13660

• Make sure the oil levels in both front fork 

legs are equal.

• Uneven oil levels can result in poor han-

dling and a loss of stability.

NOTE:

• When assembling the front fork leg, be sure to 

replace the following parts:

– Inner tube bushing
– Outer tube bushing
– Oil seal
– Dust seal

• Before assembling the front fork leg, make 

sure all of the components are clean.

1. Install:

• Inner tube bushing “1”
• Damper rod “2”
• Rebound spring
• Spring “3”
• Oil flow stopper “4”

CAUTION:

EC1D71012

Allow the damper rod to slide slowly down 
the inner tube “5” until it protrudes from the 
bottom of the inner tube. Be careful not to 
damage the inner tube.

 

Fork spring free length

273.9 mm (10.78 in)

Limit

268.4 mm (10.57 in)

FRONT FORK

4-66

2. Lubricate:

• Inner tube’s outer surface

3. Install:

• Inner tube

(in the outer tube)

4. Install:

• Copper washer 
• Damper rod bolt

5. Tighten:

• Damper rod bolt “1”

NOTE:

While holding the damper rod assembly with the 
damper rod holder “2” and T-handle “3”, tighten 
the damper rod bolt.

6. Install:

• Outer tube bushing “1”

• Washer

(with the fork seal driver “2”)

7. Install:

• Oil seal “1”

(with the fork seal driver “2”)

CAUTION:

ECA14220

Make sure the numbered side of the oil seal 
faces up.

NOTE:

• Before installing the oil seal, lubricate its lips 

with lithium-soap-based grease.

• Lubricate the outer surface of the inner tube 

with fork oil.

• Before installing the oil seal, cover the top of 

the front fork leg with a plastic bag to protect 
the oil seal during installation.

 

Recommended oil

Fork oil 10WT

T

 

R

.

 

Damper rod bolt

40 Nm (4.0 m·kg, 29 ft·lb)
LOCTITE

®

 

Damper rod holder

90890-01460

T-handle

90890-01326

T-handle 3/8" drive 60 cm long

YM-01326

4

3

2

1

5

New

 

Fork seal driver

90890-01442

Adjustable fork seal driver (36–46 
mm)

YM-01442

FRONT FORK

4-67

8. Install:

• Oil seal clip “1”

NOTE:

Adjust the oil seal clip so that it fits into the outer 
tube’s groove.

9. Install:

• Dust seal “1”

(with the fork seal driver weight “2”)

10.Fill:

• Front fork leg

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

11.Measure:

• Front fork leg oil level “a”

(from the top of the inner tube, with the outer 
tube fully compressed and without the fork 
spring)
Out of specification 

→

 Correct.

NOTE:

• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up 

and down to distribute the fork oil.

12.Install:

• Spring “1”
• Spring seat “2”
• Spacer
• Cap bolt

(with O-ring)

NOTE:

• Install the spring with the smaller pitch facing 

up.

• Before installing the cap bolt, lubricate its O-

ring with grease.

• Temporarily tighten the cap bolt.

 

Fork seal driver

90890-01442

Adjustable fork seal driver (36–46 
mm)

YM-01442

1

2

 

Quantity

571.0 cm³ (19.31 US oz) (20.10 
Imp.oz)

Recommended oil

Fork oil 10WT

 

Level

124.0 mm (4.88 in)

FRONT FORK

4-68

EAS23050

INSTALLING THE FRONT FORK LEGS

The following procedure applies to both of the 
front fork legs.
1. Install:

• Lower front fork cover “1”
• Front fork leg “2”
• Upper bracket “3”

Temporarily tighten the lower bracket pinch 
bolts and steering stem nut.

NOTE:

Make sure the inner tube end is flush with the top 
of the upper bracket.

2. Tighten:

• Lower bracket pinch bolts

3. Remove:

• Upper bracket

4. Tighten:

• Lower front fork cover nuts

5. Install:

• Upper front fork cover “1”
• Upper bracket

NOTE:

Align the groove “a” in the upper front fork cover 
“1” with the lower front fork cover nut “2”.

6. Tighten:

• Steering stem nut

• Cap bolt

• Upper bracket pinch bolts

NOTE:

Tighten the upper bracket pinch bolts to specifi-
cation twice. Tighten the upper and lower bolts 
alternately, starting with the upper bolts.

• Upper bracket cover bolts

• Upper bracket cover bolts

WARNING

EWA13680

Make sure the brake hoses are routed prop-
erly.

T

 

R

.

 

Lower bracket pinch bolt

23 Nm (2.3 m·kg, 17 ft·lb)

T

 

R

.

 

Lower front fork cover nut

7 Nm (0.7 m·kg, 5.1 ft·lb)

1

2

1

3

2

T

 

R

.

 

Steering stem nut

115 Nm (11.5 m·kg, 85 ft·lb)

T

 

R

.

 

Cap bolt

23 Nm (2.3 m·kg, 17 ft·lb)

T

 

R

.

 

Upper bracket pinch bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE

®

T

 

R

.

 

Upper bracket cover bolt

19 Nm (1.9 m·kg, 13 ft·lb)
LOCTITE

®

T

 

R

.

 

Upper bracket cover bolt

16 Nm (1.6 m·kg, 11 ft·lb)
LOCTITE

®

1

2

a

STEERING HEAD

4-69

EAS23090

STEERING HEAD

Removing the lower bracket

Order

Job/Parts to remove

Q’ty

Remarks

Lower handlebar holder

Refer to “HANDLEBAR” on page 4-55.

Upper bracket/Front fork legs

Refer to “FRONT FORK” on page 4-60.

1

Headlight bracket and throttle cable guide

1

2

Front brake hose guide

1

3

Front brake hose joint

1

4

Lock washer

1

5

Upper ring nut

1

6

Rubber washer

1

7

Lower  ring  nut

1

8

Lower bracket

1

9

Upper bearing cover

1

10

Upper bearing

1

11

Lower bearing

1

12

Dust seal

1

8

1

3

2

12

11

13

13

10

9

7

6

5

4

LS

LS

LS

T

 

R

1st   52 Nm (5.2 m 

•

 kg, 37 ft 

•

 lb)

2nd  18 Nm (1.8 m 

•

 

kg, 13 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

LT

LT

T

 

R

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)