Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 19

ELECTRIC STARTER

5-80

7. Check:

• Gear teeth

Damage/wear 

→

 Replace the gear.

8. Check:

• Bearings
• Oil seal

Damage/wear 

→

 Replace the defective 

part(s).

EAS24800

ASSEMBLING THE STARTER MOTOR

1. Install:

• Starter motor yoke “1”

NOTE:

Align the projection “a” on the brush holder with 
the slot “b” in the starter motor yoke.

2. Install:

• Starter motor front cover “1”

NOTE:

Align the match mark “a” on the starter motor 
yoke with the match mark “b” on the starter mo-
tor front cover.

1

b

a

a

b

1

TRANSFER GEAR CASE

5-81

EAS25460

TRANSFER GEAR CASE

Removing the middle driven shaft

Order

Job/Parts to remove

Q’ty

Remarks

Rider seat/Right side cover

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

Engine oil

Drain.
Refer to “CHANGING THE ENGINE OIL” on 
page 3-11.

Transfer gear oil

Drain.
Refer to “CHANGING THE TRANSFER 
GEAR OIL” on page 3-14.

Muffler/Exhaust pipes

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

Clutch release cylinder

Refer to “CLUTCH” on page 5-50.

Drive pulley

Refer to “BELT DRIVE” on page 4-80.

1

Oil pipe 2

1

2

Oil pipe 4

1

3

Transfer gear case cover

1

4

Transfer gear case gasket

1

5

Dowel pin

2

6

Transfer gear oil pump assembly

1

7

Dowel pin

2

8

6

7

1

2

3

12

10

5

5

4

9

(7)

(5)

13

New

New

7

E

New

New

New

New

New

New

11

LS

LS

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

8 Nm (0.8 m

 

•

 kg, 5.8 ft 

•

 Ib)

 

R

18 Nm (1.8 m 

•

 

kg, 13 ft

 

•

 

Ib)

 

R

140 Nm (14.0 m 

•

 kg, 100 ft 

•

 lb)

T

 

R

40 Nm (4.0 m 

•

 

kg, 29 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)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

T

 

R

5 Nm (0.5 m

 

•

 kg, 3.6 ft 

•

 Ib)

TRANSFER GEAR CASE

5-82

8

Oil strainer

1

9

Gasket

1

10

Conical spring washer

1

11

Primary chain

1

12

Middle drive gear

1

13

Middle driven shaft

1

For installation, reverse the removal proce-
dure.

Removing the middle driven shaft

Order

Job/Parts to remove

Q’ty

Remarks

8

6

7

1

2

3

12

10

5

5

4

9

(7)

(5)

13

New

New

7

E

New

New

New

New

New

New

11

LS

LS

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

8 Nm (0.8 m

 

•

 kg, 5.8 ft 

•

 Ib)

 

R

18 Nm (1.8 m 

•

 

kg, 13 ft

 

•

 

Ib)

 

R

140 Nm (14.0 m 

•

 kg, 100 ft 

•

 lb)

T

 

R

40 Nm (4.0 m 

•

 

kg, 29 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)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

T

 

R

5 Nm (0.5 m

 

•

 kg, 3.6 ft 

•

 Ib)

TRANSFER GEAR CASE

5-83

Disassembling the transfer gear oil pump

Order

Job/Parts to remove

Q’ty

Remarks

1

Transfer gear oil pump cover

1

2

Transfer gear oil pump outer rotor

1

3

Transfer gear oil pump inner rotor

1

4

Pin

1

5

Washer

1

6

Transfer gear oil pump shaft

1

7

Transfer gear oil pump housing

1

For assembly, reverse the disassembly pro-
cedure.

5

7

6

3

2

1

(6)

T

 

R

4 Nm (0.4 m

 

•

 kg, 2.9 ft 

•

 Ib)

E

4

TRANSFER GEAR CASE

5-84

Removing the transfer gear case

Order

Job/Parts to remove

Q’ty

Remarks

Horn 2 connector

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

Battery box

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

Sub-fuel tank

Refer to “FUEL TANK” on page 6-1.

1

Oil tank breather hose

1

Disconnect.

2

Speed sensor

1

3

Oil tank damper

1

4

Dipstick

1

5

Dipstick joint

1

6

Drive pulley case

1

7

Dowel pin

2

8

Spacer

1

9

Transfer gear case

1

10

Dowel pin

2

For installation, reverse the removal proce-
dure.

LS

LS

LS

New

New

New

New

New

3

2

10

(4)

1

7

8

4

5

9

(8)

6

LT

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

70 Nm (7.0 m 

•

 kg, 50 ft 

•

 lb)

T

 

R

50 Nm (5.0 m 

•

 

kg, 36 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

LS

E

E

TRANSFER GEAR CASE

5-85

Disassembling the oil tank

Order

Job/Parts to remove

Q’ty

Remarks

1

Sub-fuel tank bracket

1

2

Oil tank cover

1

3

Oil tank cover gasket

1

4

Dowel pin

2

5

Oil strainer

1

6

Oil pipe 5

1

7

Oil tank

1

For assembly, reverse the disassembly pro-
cedure.

3

2

(15)

4

5

6

1

7

New

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

28 Nm (2.8 m 

•

 

kg, 20 ft

 

•

 

Ib)

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

New

New

 

R

43 Nm (4.3 m 

•

 

kg, 31 ft

 

•

 

Ib)

LT

New

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

TRANSFER GEAR CASE

5-86

EAS25470

REMOVING THE MIDDLE DRIVEN SHAFT

NOTE:

Loosen the middle drive gear nut before remove 
the drive pulley.

1. Install:

• Right rider footrest assembly

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

2. Loosen:

• Middle drive gear nut “1”

NOTE:

When loosening the middle drive gear nut, press 
down on the brake pedal so the middle drive 
gear does not move.

3. Remove:

• Primary chain “1”
• Middle drive gear “2”
• Middle driven shaft “3”

NOTE:

Remove the primary chain, middle drive gear 
and middle driven shaft at the same time.

EAS25480

CHECKING THE MIDDLE DRIVE

1. Check:

• Middle drive gear
• Middle driven gear

Damage/wear 

→

 Replace the middle drive 

gear, middle driven shaft and primary chain 
as a set.

2. Check:

• Primary chain

Damage/stiffness 

→

 Replace the primary 

chain, middle drive gear and middle driven 
shaft as a set.

EAS25490

CHECKING THE OIL STRAINER

1. Check:

• Oil strainer

Damage 

→

 Replace.

Contaminants 

→

 Clean with engine oil.

EAS25500

CHECKING THE TRANSFER GEAR OIL 
PUMP

1. Check:

• Transfer gear oil pump housing
• Transfer gear oil pump cover

Cracks/damage/wear 

→

 Replace the defec-

tive part(s).

2. Measure:

• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance 

“b”

• Oil-pump-housing-to-inner-rotor-and-outer-

rotor clearance “c”
Out of specification 

→

 Replace the transfer 

gear oil pump.

1

1

2 

3

1. Transfer gear oil pump inner rotor
2. Transfer gear oil pump outer rotor
3. Transfer gear oil pump housing

TRANSFER GEAR CASE

5-87

3. Check:

• Transfer gear oil pump operation

Rough movement 

→

 Repeat steps (1) and 

(2) or replace the defective part(s).

EAS25510

CHECKING THE OIL PIPES

1. Check:

• Oil pipes

Damage 

→

 Replace.

EAS25520

ASSEMBLING THE TRANSFER GEAR OIL 
PUMP

1. Lubricate:

• Transfer gear oil pump inner rotor
• Transfer gear oil pump outer rotor
• Transfer gear oil pump shaft

(with the recommended lubricant)

2. Install:

• Transfer gear oil pump shaft “1”

(to the transfer gear oil pump housing “2”)

• Washer “3”
• Pin “4”
• Transfer gear oil pump inner rotor “5”

• Transfer gear oil pump outer rotor “6”
• Transfer gear oil pump cover “7”

NOTE:

When installing the inner rotor, align the pin in 
the oil pump shaft with the groove in the inner ro-
tor.

3. Check:

• Transfer gear oil pump operation

Refer to “CHECKING THE TRANSFER 
GEAR OIL PUMP” on page 5-86.

EAS25530

INSTALLING THE TRANSFER GEAR CASE

1. Install:

• Spacer “1”

NOTE:

Install the spacer with its groove “a” towards the 
drive pulley.

2. Install:

• Middle driven shaft “1”
• Middle drive gear “2”
• Primary chain “3”

(into the transfer gear case)

• Drive pulley nut

NOTE:

• Install the primary chain with its blue link “a” 

facing outward.

 

Inner-rotor-to-outer-rotor-tip 
clearance

Less than 0.12 mm (0.0047 in)

Limit

0.20 mm (0.0079 in)

Outer-rotor-to-oil-pump-housing 
clearance

0.10–0.15 mm (0.0039–0.0059 in)

Limit

0.22 mm (0.0087 in)

Oil-pump-housing-to-inner-and-
outer-rotor clearance

0.04–0.09 mm (0.0016–0.0035 in)

Limit

0.160 mm (0.0063 in)

 

Recommended lubricant

Engine oil

T

 

R

.

 

Oil pump housing screw

4 Nm (0.4 m·kg, 2.9 ft·lb)

3

2

1

5

6

7

(6)

4

E

1

a

TRANSFER GEAR CASE

5-88

• Install the middle drive gear “2” with its cham-

fered side facing “b” the transfer gear case.

• Install the middle driven shaft, middle drive 

gear and primary chain at the same time.

• Align the splines on the middle drive gear with 

the splines on the drive axle.

• Temporarily install the drive pulley nut onto the 

middle driven shaft.

3. Install:

• Conical spring washer “1”

• Middle drive gear nut “2” 

NOTE:

• Lubricate the middle drive gear nut threads 

and conical spring washer mating surfaces 
with engine oil.

• Install the conical spring washer “1” with the 

“OUT” mark “a” facing out.

• Stake the middle drive gear nut “2” at a cutout 

“b” in the drive axle.

4. Remove:

• Drive pulley nut

T

 

R

.

 

Middle drive gear nut

140 Nm (14.0 m·kg, 100 ft·lb)

3

2 

1

a

b

2

New

2

New

b

1

a

CRANKCASE

5-89

EAS25540

CRANKCASE

Separating the crankcase

Order

Job/Parts to remove

Q’ty

Remarks

Engine

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

Camshafts

Refer to “CAMSHAFTS” on page 5-14.

Pistons

Refer to “CYLINDERS AND PISTONS” on 
page 5-45.

Left balancer driven gear housing

Refer to “CLUTCH” on page 5-50.

Shift shaft

Refer to “SHIFT SHAFT” on page 5-70.

Generator rotor

Refer to “GENERATOR AND STARTER 
CLUTCH” on page 5-72.

1

Neutral switch

1

2

Oil pipe 3

1

3

Oil strainer

2

4

Oil delivery pipe 3

1

5

Engine oil pump driven gear stopper

1

6

Engine oil pump driven gear

1

7

Oil baffle plate (left crankcase)

1

8

Left crankcase

1

9

Dowel pin

2

New

1

11

9

4

5

6

2

(5)

7

3

13

8

9

10

12

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

24 Nm (2.4 m 

•

 

kg, 17 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

3

New

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

New

LT

New

New

LS

New

New

(6)

LS

LT

LT

 

R

43 Nm (4.3 m 

•

 

kg, 31 ft

 

•

 

Ib)

(4)

LS

LT

(4)

(4)

(8)

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

LT

CRANKCASE

5-90

10

Joint pipe

1

11

Oil pipe

1

“R” mark

12

Oil pipe

1

“F” mark

13

Right crankcase

1

For installation, reverse the removal proce-
dure.

Separating the crankcase

Order

Job/Parts to remove

Q’ty

Remarks

New

1

11

9

4

5

6

2

(5)

7

3

13

8

9

10

12

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

24 Nm (2.4 m 

•

 

kg, 17 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

3

New

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

New

LT

New

New

LS

New

New

(6)

LS

LT

LT

 

R

43 Nm (4.3 m 

•

 

kg, 31 ft

 

•

 

Ib)

(4)

LS

LT

(4)

(4)

(8)

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

LT

CRANKCASE

5-91

Removing the oil seals and bearings

Order

Job/Parts to remove

Q’ty

Remarks

Oil pump

Refer to “OIL PUMP” on page 5-95.

Crankshaft

Refer to “CRANKSHAFT” on page 5-101.

Transmission

Refer to “TRANSMISSION” on page 5-107.

1

Oil baffle plate (right crankcase)

1

2

Bearing retainer

2

3

Bearing retainer

2

4

Oil seal

2

5

Bearing

4

For installation, reverse the removal proce-
dure.

LS

4

2

1

3

3

5

5

T

 

R

20 Nm (2.0 m 

•

 

kg, 14 ft

 

•

 

Ib)

LT

New

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LT

LT

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

New

E

LT

LT

New

E

5

5

LS

CRANKCASE

5-92

EAS25570

DISASSEMBLING THE CRANKCASE

1. Remove:

• Crankcase bolts

NOTE:

• Loosen each bolt 1/4 of a turn at a time, in stag-

es and in a crisscross pattern. After all of the 
bolts are fully loosened, remove them.

• Loosen the bolts in decreasing numerical order 

(refer to the numbers in the illustration).

• M8 

×

 90 mm bolts: “1”, “2”

• M8 

×

 65 mm bolt: “3”

• M6 

×

 100 mm bolts: “4”, “9”–“11”

• M6 

×

 80 mm bolt: “12”

• M6 

×

 70 mm bolts: “13”–“16”

• M6 

×

 60 mm bolts: “5”–“8”

• M6 

×

 35 mm bolts: “17”–“24”

2. Remove:

• Left crankcase

CAUTION:

ECA13900

Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase 
mating surfaces. Work slowly and carefully 
and make sure the crankcase halves sepa-
rate evenly.

EAS25580

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a 

mild solvent.

2. Thoroughly clean all the gasket surfaces and 

crankcase mating surfaces.

3. Check:

• Crankcase

Cracks/damage 

→

 Replace.

• Oil delivery passages

Obstruction 

→

 Blow out with compressed air.

ET1D71005

CHECKING THE BEARINGS AND OIL SEAL

1. Check:

• Bearings

Clean and lubricate the bearings, then rotate 
the inner race with your finger.
Rough movement 

→

 Replace.

• Oil seals

Damage/wear 

→

 Replace.

EAS25590

CHECKING THE OIL DELIVERY PIPE AND 
OIL PIPE

1. Check:

• Oil delivery pipe
• Oil pipes

Damage 

→

 Replace.

Obstruction 

→

 Wash and blow out with com-

pressed air.

ET1D71038

CHECKING THE OIL STRAINERS

1. Check:

• Oil strainers

Damage 

→

 Replace.

Contaminants 

→

 Clean with solvent.

A. Right crankcase
B. Left crankcase

4

1

5

3

6

7

2 

8

A

21

20 16 15

14 19

17

18

12

10

9

22

23

13

11

24

B

CRANKCASE

5-93

EAS25610

CHECKING THE ENGINE OIL PUMP DRIVEN 
GEAR

1. Check:

• Engine oil pump driven gear

Chips/pitting/roughness/wear 

→

 Replace.

ET1D71034

INSTALLING THE BEARING RETAINERS

1. Install:

• Bearing retainers “1”

NOTE:

• Apply locking agent (LOCTITE

®

) to the threads 

of the bearing retainer bolts.

• Stake the bearing retainer bolts “2”.

EAS25690

ASSEMBLING THE CRANKCASE

1. Apply:

• Sealant

(onto the crankcase mating surfaces)

NOTE:

Do not allow any sealant to come into contact 
with the oil gallery.

2. Install:

• Oil pipe (“F” mark) “1”
• Oil pipe (“R” mark) “2”
• Dowel pins “3”

• Joint pipe “4”

3. Install:

• Left crankcase

(onto the right crankcase)

NOTE:

Tap lightly on the left crankcase with a soft-face 
hammer.

4. Install:

• Crankcase bolts (M6)
• Crankcase bolts (M8)

NOTE:

• Lubricate the bolt threads with engine oil.
• Tighten each bolt 1/4 of a turn at a time, in stag-

es and in a crisscross pattern.

• Tighten the bolts in numerical order (refer to 

the numbers in the illustration).

• M8 

×

 90 mm bolts: “1”, “2”

• M8 

×

 65 mm bolt: “3”

• M6 

×

 100 mm bolts: “4”, “9”–“11”

• M6 

×

 80 mm bolt: “12”

• M6 

×

 70 mm bolts: “13”–“16”

• M6 

×

 60 mm bolts: “5”–“8”

• M6 

×

 35 mm bolts: “17”–“24”

 

Yamaha bond No. 1215

90890-85505
(Three Bond No.1215

®

)

2

2

1

1

T

 

R

.

 

Crankcase bolt (M6)

10 Nm (1.0 m·kg, 7.2 ft·lb)

Crankcase bolt (M8)

24 Nm (2.4 m·kg, 17 ft·lb)

3

3

4

1

2

CRANKCASE

5-94

5. Apply:

• Engine oil

(onto the crankshaft pin bearings and oil de-
livery holes)

6. Check:

• Crankshaft and transmission operation

Rough movement 

→

 Repair.

A. Right crankcase
B. Left crankcase

4

1

5

3

6

7

2 

8

A

21

20 16 15

14 19

17

18

12

10

9

22

23

13

11

24

B

OIL PUMP

5-95

EAS24910

OIL PUMP

Removing the oil pump

Order

Job/Parts to remove

Q’ty

Remarks

Crankcase

Separate.
Refer to “CRANKCASE” on page 5-89.

1

Oil pump assembly

1

For installation, reverse the removal proce-
dure.

1

T

 

R

24 Nm (2.4 m 

•

 

kg, 17 ft

 

•

 

Ib)