Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 20

OIL PUMP

5-96

Disassembling the oil pump

Order

Job/Parts to remove

Q’ty

Remarks

1

Oil pump housing cover 1

1

2

Oil scavenging pump outer rotor 1

1

3

Oil scavenging pump inner rotor 1

1

4

Pin

1

5

Oil pump housing 1

1

6

Oil strainer

1

7

Pin

2

8

Ball spring

1

9

Oil scavenging pump outer rotor 2

1

10

Oil scavenging pump inner rotor 2

1

11

Pin

1

12

Oil pump housing cover 2

1

13

Relief valve spring

1

14

Relief valve

1

15

Oil feed pump outer rotor

1

16

Oil feed pump inner rotor

1

17

Pin

1

E

E

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

5

3

12

15

16

17

2

1

9

7

7

14

13

20

21

22

23

8

10

6

11

4

19

18

24

New

New

New

E

OIL PUMP

5-97

18

Oil pump shaft

1

19

Oil seal

1

20

Circlip

1

21

Oil seal

1

22

Ball

1

23

Ball guide

1

24

Oil pump housing 2

1

For assembly, reverse the disassembly pro-
cedure.

Disassembling the oil pump

Order

Job/Parts to remove

Q’ty

Remarks

E

E

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

5

3

12

15

16

17

2

1

9

7

7

14

13

20

21

22

23

8

10

6

11

4

19

18

24

New

New

New

E

OIL PUMP

5-98

EAS24960

CHECKING THE OIL PUMP

1. Check:

• Oil pump housing
• Oil pump housing 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 oil pump.

3. Check:

• Oil pump operation

Rough movement 

→

 Repeat steps (1) and 

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

EAS24970

CHECKING THE RELIEF VALVE

1. Check:

• Relief valve body
• Relief valve
• Relief valve spring

Damage/wear 

→

 Replace the defective 

part(s).

ET1D71035

CHECKING THE BALL SPRING AND RELIEF 
VALVE SPRING

1. Measure:

• Ball spring free length
• Relief valve spring free length

Out of specification 

→

 Replace the defective 

part(s).

 

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

Less than 0.12 mm (0.0047 in)

Limit

0.20 mm (0.0079 in)

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

0.06–0.13 mm (0.0024–0.0051 in)

Limit

0.20 mm (0.0079 in)

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

0.09–0.19 mm (0.0035–0.0075 in)

Limit

0.26 mm (0.0102 in)

1. Inner rotor
2. Outer rotor
3. Oil pump housing

 

Ball spring

Free length

34.70 mm (1.37 in)

Limit

32.97 mm (1.30 in)

Relief valve spring

Free length

28.95 mm (1.14 in)

Limit

27.50 mm (1.08 in)

a. Free length

OIL PUMP

5-99

2. Measure:

• Ball spring force
• Relief valve spring force

Out of specification 

→

 Replace the defective 

part(s).

EAS24990

CHECKING THE OIL STRAINER

1. Check:

• Oil strainer “1”

Damage 

→

 Replace.

Contaminants 

→

 Clean with solvent.

EAS25000

ASSEMBLING THE OIL PUMP

1. Lubricate:

• Inner rotor
• Outer rotor

• Oil pump shaft

(with the recommended lubricant)

2. Install:

• Oil pump housing 2 “1”
• Ball guide “2”
• Ball “3”

• Oil seal “4” 

• Circlip “5” 

• Oil seal “6” 
• Oil pump shaft “7”
• Pin “8”
• Oil feed pump inner rotor “9”
• Oil feed pump outer rotor “10”
• Relief valve “11”
• Relief valve spring “12”
• Oil pump housing cover 2 “13”

• Pin “14”
• Oil scavenging pump inner rotor 2 “15”
• Oil scavenging pump outer rotor 2 “16”
• Ball spring “17”
• Pins “18”
• Oil strainer “19”
• Oil pump housing 1 “20”
• Pin “21”
• Oil scavenging pump inner rotor 1 “22”
• Oil scavenging pump outer rotor 1 “23”
• Oil pump housing cover 1 “24”

NOTE:

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

 

Ball spring

Installed compression spring 
force

2.23 N (0.60 lb) (0.27 kgf) or less

Installed length

29.4 mm (1.12 in)

Relief valve spring

Installed compression spring 
force

52.4 N (11.78 lb) (5.34 kgf) or 
less

Installed length

16.8 mm (0.66 in)

a. Spring force
b. Installed length

1

 

Recommended lubricant

Engine oil

T

 

R

.

 

Oil pump housing cover 2 screw

7 Nm (0.7 m·kg, 5.1 ft·lb)

T

 

R

.

 

Oil pump housing cover 1 screw

7 Nm (0.7 m·kg, 5.1 ft·lb)

New

New

New

OIL PUMP

5-100

3. Check:

• Oil pump operation

Refer to “CHECKING THE OIL PUMP” on 
page 5-98.

EAS25020

INSTALLING THE OIL PUMP

1. Install:

• Oil pump assembly “1”

CAUTION:

ECA13890

After tightening the bolts, make sure the oil 
pump turns smoothly.

T

 

R

.

 

Oil pump assembly bolt

24 Nm (2.4 m·kg, 17 ft·lb)

E

E

20

22

13

10

9

8

23

24

16

18

18

11

12

5

4

3 2

17

15 

19

14 21

6

7

1

New

New

New

E

1

CRANKSHAFT

5-101

EAS25960

CRANKSHAFT

Removing the crankshaft

Order

Job/Parts to remove

Q’ty

Remarks

Crankcase

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

1

Crankshaft

1

2

Generator shaft

1

3

Connecting rod cap

2

4

Big end lower bearing

2

5

Connecting rod

2

6

Big end upper bearing

2

For installation, reverse the removal proce-
dure.

CRANKSHAFT

5-102

EAS26010

REMOVING THE CONNECTING RODS

1. Remove:

• Connecting rod caps “1”
• Connecting rods
• Big end bearings

NOTE:

Identify the position of each big end bearing so 
that it can be reinstalled in its original place.

EAS26090

CHECKING THE CRANKSHAFT AND 
CONNECTING RODS

1. Measure:

• Crankshaft runout

Out of specification 

→

 Replace the crank-

shaft.

2. Check:

• Crankshaft journal surfaces
• Crankshaft pin surfaces
• Bearing surfaces

Scratches/wear 

→

 Replace the crankshaft.

• Generator shaft drive gear “1”

Damage/wear 

→

 Replace the crankshaft.

3. Measure:

• Crankshaft-pin-to-big-end-bearing clearance

Out of specification 

→

 Replace the big end 

bearings.

The following procedure applies to all of the 
connecting rods.

CAUTION:

ECA13930

Do not interchange the big end bearings and 
connecting rods. To obtain the correct 
crankshaft-pin-to-big-end-bearing clear-
ance and prevent engine damage, the big 
end bearings must be installed in their origi-
nal positions.

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Clean the big end bearings, crankshaft pins, 

and the inside of the connecting rod halves.

b. Install the big end upper bearing into the con-

necting rod and the big end lower bearing into 
the connecting rod cap.

NOTE:

Align the projections “a” on the big end bearings 
with the notches “b” in the connecting rod and 
connecting rod cap.

c. Put a piece of Plastigauge

®

 “1” on the crank-

shaft pin.

 

Runout limit C

0.040 mm (0.0016 in)

 

Journal oil clearance (using plas-
tigauge

®

)

0.030–0.060 mm (0.0012–0.0024 
in)

CRANKSHAFT

5-103

d. Assemble the connecting rod halves.

NOTE:

• Do not move the connecting rod or crankshaft 

until the clearance measurement has been 
completed.

• Lubricate the bolts threads with molybdenum 

disulfide grease.

• Make sure the projection “c” on the connecting 

rod faces towards the left side of the crank-
shaft.

• Make sure the characters “d” on both the con-

necting rod and connecting rod cap are 
aligned.

e. Tighten the connecting rod bolts.

WARNING

EWA12890

• Replace the connecting rod bolts with new 

ones.

• Clean the connecting rod bolts.

NOTE:

The tightening procedure of the connecting rod 
bolts is angle controlled, therefore tighten the 
bolts using the following procedure.

f. Tighten the connecting rod bolts to the spec-

ified torque.

g. Put a mark “1” on the connecting rod bolts “2” 

and the connecting rod cap “3”.

h. Tighten the connecting rod bolts further to 

reach the specified angle 125–135°.

WARNING

EW1D71011

When a bolt is tightened more than the spec-
ified angle, do not loosen and then retighten 
it.
Replace the bolt with a new one and perform 
the procedure again.

CAUTION:

EC1D71001

• Do not use a torque wrench to tighten the 

bolt to the specified angle.

• Tighten the bolt until it is at the specified 

angle.

i. Remove the connecting rod and big end 

bearings.

j. Measure the compressed Plastigauge

®

 width 

“e” on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing 
clearance is out of specification, select re-
placement big end bearings.

T

 

R

.

 

Connecting rod bolt (1st)

15 Nm (1.5 m·kg, 11 ft·lb)

T

 

R

.

 

Connecting rod bolt (final)

Specified angle 125–135°

CRANKSHAFT

5-104

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

4. Select:

• Big end bearings (“P

1

”–“P

2

”)

NOTE:

• The numbers “a” stamped into the crankshaft 

web and the numbers “b” on the connecting 
rods are used to determine the replacement 
big end bearing sizes.

• “P

1

”–“P

2

” refer to the bearings shown in the 

crankshaft illustration.

For example, if the connecting rod “P

1

” and 

the crankshaft web “P” numbers are “5” and 
“2” respectively, then the bearing size for “P

1

” 

is:

5. Measure:

• Crankshaft journal diameter “a”

Out of specification 

→

 Replace the crank-

shaft.

NOTE:

Measure the diameter of each crankshaft journal 
at two places.

6. Measure:

• Crankshaft journal bearing inside diameter 

“a”
Out of specification 

→

 Replace the crank-

case assembly.

NOTE:

Measure the inside diameter of each crankshaft 
journal bearing at two places.

P

1

P

2

a

“P

1

” (connecting rod) - “P” (crankshaft)

=
5 - 2 = 3 (brown)

 

Bearing color code

1.Blue 2.Black 3.Brown 4.Green 
5.Yellow

 

Crankshaft journal diameter

49.968–49.980 mm (1.9672–
1.9677 in)

 

Crankshaft journal bearing inside 
diameter

50.010–50.030 mm (1.9689–
1.9697 in)

CRANKSHAFT

5-105

7. Calculate:

• Crankshaft journal-to-crankshaft journal 

bearing clearance
Out of specification 

→

 Replace the crank-

shaft and crankshaft journal bearings as a 
set.

NOTE:

Calculate the clearance by subtracting the 
crankshaft journal diameter from the crankshaft 
journal bearing inside diameter.

EAS26150

INSTALLING THE CONNECTING RODS

1. Lubricate:

• Bolt threads

(with the recommended lubricant)

2. Lubricate:

• Crankshaft pins
• Big end bearings
• Connecting rod inner surface

(with the recommended lubricant)

3. Install:

• Big end bearings
• Connecting rods
• Connecting rod caps

(onto the crankshaft pins)

NOTE:

• Align the projections “a” on the big end bear-

ings with the notches “b” in the connecting rods 
and connecting rod caps.

• Be sure to reinstall each big end bearing in its 

original place.

• Make sure the projection “c” on the connecting 

rods face towards the left side of the crank-
shaft.

• Make sure the characters “d” on both the con-

necting rod and connecting rod cap are 
aligned.

4. Tighten:

• Connecting rod bolts “1”

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

WARNING

EWA12890

• Replace the connecting rod bolts with new 

ones.

• Clean the connecting rod bolts.

NOTE:

The tightening procedure of the connecting rod 
bolts is angle controlled, therefore tighten the 
bolts using the following procedure.

 

Crankshaft journal-to-crankshaft 
journal bearing clearance

0.030–0.060 mm (0.0012–0.0024 
in)

 

Recommended lubricant

Molybdenum disulfide grease

 

Recommended lubricant

Engine oil

CRANKSHAFT

5-106

a. Tighten the connecting rod bolts with a torque 

wrench.

b. Put a mark “1” on the corner of the connecting 

rod bolts “2” and the connecting rod “3”.

c. Tighten the connecting rod bolts further to 

reach the specified angle 125–135°.

WARNING

EW1D71011

When a bolt is tightened more than the spec-
ified angle, do not loosen and then retighten 
it.
Replace the bolt with a new one and perform 
the procedure again.

CAUTION:

EC1D71001

• Do not use a torque wrench to tighten the 

bolt to the specified angle.

• Tighten the bolt until it is at the specified 

angle.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

EAS26210

INSTALLING THE CRANKSHAFT 
ASSEMBLY

1. Install:

• Generator shaft “1”

• Crankshaft assembly “2”

CAUTION:

ECA13970

To avoid scratching the crankshaft and to 
ease the installation procedure, lubricate the 
oil seal lips with lithium-soap-based grease 
and each bearing with engine oil.

NOTE:

• Make sure that the generator shaft drive gear 

teeth and generator shaft driven gear teeth 
mesh correctly.

• Align the punch mark “a” on the generator shaft 

driven gear with the punch mark “b” on the gen-
erator shaft drive gear.

• Align the right connecting rod with the front cyl-

inder sleeve hole.

T

 

R

.

 

Connecting rod bolt (1st)

15 Nm (1.5 m·kg, 11 ft·lb) 

T

 

R

.

 

Connecting rod bolt (final)

Specified angle 125–135°

1

2

b

a

TRANSMISSION

5-107

EAS26240

TRANSMISSION

Removing the transmission, shift drum assembly, and shift forks

Order

Job/Parts to remove

Q’ty

Remarks

Crankcase

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

1

Shift fork guide bar

2

2

Shift drum assembly

1

3

Shift fork 1

2

4

Shift fork 2

1

5

Drive axle assembly

1

6

Main axle assembly

1

7

Spacer

1

For installation, reverse the removal proce-
dure.

New

4

6

5

1

7

2

3

3

LS

E

E

1

E

M

M

TRANSMISSION

5-108

Disassembling the main axle assembly

Order

Job/Parts to remove

Q’ty

Remarks

1

2nd pinion gear

1

2

Toothed lock washer

1

3

Toothed lock washer retainer

1

4

5th pinion gear

1

5

Collar

1

6

Toothed washer

1

7

Circlip

1

8

3rd pinion gear

1

9

Circlip

1

10

Toothed washer

1

11

4th pinion gear

1

12

Collar

1

13

Main axle/1st pinion gear

1

For assembly, reverse the disassembly pro-
cedure.

TRANSMISSION

5-109

Disassembling the drive axle assembly

Order

Job/Parts to remove

Q’ty

Remarks

1

Circlip

1

2

Washer

1

3

1st wheel gear

1

4

Collar

1

5

4th wheel gear

1

6

Circlip

1

7

Toothed washer

1

8

3rd wheel gear

1

9

Collar

1

10

Toothed lock washer

1

11

Toothed lock washer retainer

1

12

5th wheel gear

1

13

Circlip

1

14

Toothed washer

1

15

2nd wheel gear

1

16

Collar

1

TRANSMISSION

5-110

17

Drive axle

1

For assembly, reverse the disassembly pro-
cedure.

Disassembling the drive axle assembly

Order

Job/Parts to remove

Q’ty

Remarks

TRANSMISSION

5-111

EAS26260

CHECKING THE SHIFT FORKS

The following procedure applies to all of the shift 
forks.
1. Check:

• Shift fork cam follower “1”
• Shift fork pawl “2”

Bends/damage/scoring/wear 

→

 Replace the 

shift fork.

2. Check:

• Shift fork guide bar

Roll the shift fork guide bar on a flat surface.
Bends 

→

 Replace.

WARNING

EWA12840

Do not attempt to straighten a bent shift fork 
guide bar.

3. Check:

• Shift fork movement

(along the shift fork guide bar)
Rough movement 

→

 Replace the shift forks 

and shift fork guide bar as a set.

EAS26270

CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:

• Shift drum groove

Damage/scratches/wear 

→

 Replace the shift 

drum assembly.

• Shift drum segment “1”

Damage/wear 

→

 Replace the shift drum as-

sembly.

• Shift drum bearing “2”

Damage/pitting 

→

 Replace the shift drum as-

sembly.

EAS26300

CHECKING THE TRANSMISSION

1. Measure:

• Main axle runout

(with a centering device and dial gauge “1”)
Out of specification 

→

 Replace the main axle.

2. Measure:

• Drive axle runout

(with a centering device and dial gauge “1”)
Out of specification 

→

 Replace the drive axle.

 

Main axle runout limit

0.08 mm (0.0032 in)

 

Drive axle runout limit

0.08 mm (0.0032 in)