Yamaha XV19CTWC Manuals

Manuals and User Guides for Yamaha XV19CTWC. We have 1 Yamaha XV19CTWC manual available for free PDF download: Service Manual

Yamaha XV19CTWC Service Manual

Yamaha XV19CTWC Service Manual (444 pages)

Brand: Yamaha | Category: Motorcycle | Size: 20.32 MB

Table of Contents

Table of Contents

8
- How to Use this Manual
  5
- Symbols
  6
- General Information
  10
  - Identification
    11
    
    Vehicle Identification Number
    11
    
    Model Label
    11
  - Features
    12
    
    Outline of the Fi System
    12
    
    Fi System
    13
    
    Instrument Functions
    14
  - Important Information
    18
    
    Preparation for Removal and Disassembly
    18
    
    Replacement Parts
    18
    
    Gaskets, Oil Seals and O-Rings
    18
    
    Lock Washers/Plates and Cotter Pins
    18
    
    Bearings and Oil Seals
    19
    
    Circlips
    19
  - Checking the Connections
    20
  - Special Tools
    21
Specifications

26
- General Specifications
  27
- Engine Specifications
  28
- Chassis Specifications
  36
- Electrical Specifications
  39
- Tightening Torques
  42
- Lubrication Points and Lubricant Types
  53
  - Engine
    53
  - Chassis
    55
- Lubrication System Chart and Diagrams
  57
  - Engine Oil Lubrication Chart
    57
  - Lubrication Diagrams
    59
- Cable Routing
  71
Periodic Checks and Adjustments

88
- Periodic Maintenance
  
  91
- Engine
  
  94
  - Adjusting the Valve Clearance
    94
    
    Synchronizing the Throttle Bodies
    97
    
    Adjusting the Throttle Cable Free Play
    98
    
    Checking the Spark Plugs
    99
    
    Checking the Ignition Timing
    100
    
    Checking the Engine Oil Level
    101
    
    Changing the Engine Oil
    101
    
    Checking the Transfer Gear Oil Level
    103
    
    Changing the Transfer Gear Oil
    104
    
    Checking the Clutch Fluid Level
    104
    
    Bleeding the Hydraulic Clutch System
    105
    
    Replacing the Air Filter Element
    105
    
    Checking the Throttle Body Joints
    106
    
    Checking the Fuel Line
    106
    
    Checking the Cylinder Head Breather Hose
    107
    
    Checking the Oil Tank Breather Hose
    107
    
    Checking the Exhaust System
    107
    
    CHECKING the CANISTER (for California Only)
    108
    
    Adjusting the Exup Cables
    108
- Chassis
  
  110
  - Adjusting the Rear Disc Brake
    110
  - Checking the Brake Fluid Level
    110
  - Checking the Front Brake Pads
    111
  - Checking the Rear Brake Pads
    111
  - Checking the Front Brake Hoses
    111
  - Checking the Rear Brake Hoses
    112
  - Adjusting the Rear Brake Light Switch
    112
  - Bleeding the Hydraulic Brake System
    112
  - Adjusting the Shift Pedal
    113
  - Adjusting the Drive Belt Slack
    114
  - Checking and Adjusting the Steering Head
    115
  - Checking the Front Fork
    116
  - Adjusting the Rear Shock Absorber Assembly
    117
  - Checking the Tires
    117
  - Checking the Wheels
    119
  - Checking and Lubricating the Cables
    119
  - Lubricating the Levers
    120
  - Lubricating the Pedal
    120
  - Lubricating the Sidestand
    120
  - Lubricating the Rear Suspension
    120
  - Electrical System
    121
Chassis

124
- General Chassis
  
  127
  - Removing the Windshield
    128
  - Assembling the Windshield
    128
  - Installing the Windshield
    128
  - Removing the Backrest
    131
  - Assembling the Backrest
    131
  - Installing the Backrest
    131
  - Checking the Sidebag Bracket Spring Nuts
    134
- Front Wheel
  
  141
  - Removing the Front Wheel
    144
  - Disassembling the Front Wheel
    144
  - Checking the Front Wheel
    144
  - Assembling the Front Wheel
    145
  - Adjusting the Front Wheel Static Balance
    145
  - Installing the Front Wheel (Front Brake Discs)
    146
- Rear Wheel
  
  149
  - Removing the Rear Wheel (Disc)
    154
  - Disassembling the Rear Wheel
    154
  - Checking the Rear Wheel
    154
  - Checking the Rear Brake Caliper Bracket
    154
  - Checking the Rear Wheel Drive Hub
    155
  - Checking and Replacing the Rear Wheel Pulley
    155
  - Assembling the Rear Wheel
    155
  - Adjusting the Rear Wheel Static Balance
    155
  - Installing the Rear Wheel (Disc)
    155
- Front Brake
  
  157
- Rear Brake
  
  169
  - Introduction
    175
  - Checking the Rear Brake Disc
    175
  - Replacing the Rear Brake Pads
    175
  - Removing the Rear Brake Caliper
    176
  - Disassembling the Rear Brake Caliper
    176
  - Checking the Rear Brake Caliper
    177
  - Assembling the Rear Brake Caliper
    177
  - Installing the Rear Brake Caliper
    177
  - Removing the Rear Brake Master Cylinder
    178
  - Checking the Rear Brake Master Cylinder
    178
  - Assembling the Rear Brake Master Cylinder
    179
  - Installing the Rear Brake Master Cylinder
    179
- Handlebar
  
  181
  - Removing the Handlebar
    183
  - Checking the Handlebar
    183
  - Installing the Handlebar
    183
- Front Fork
  
  186
  - Removing the Front Fork Legs
    190
  - Disassembling the Front Fork Legs
    190
  - Checking the Front Fork Legs
    191
  - Assembling the Front Fork Legs
    191
  - Installing the Front Fork Legs
    194
- Steering Head
  
  195
  - Removing the Lower Bracket
    197
  - Checking the Steering Head
    197
  - Installing the Steering Head
    197
- Rear Shock Absorber Assembly and Swingarm
  
  199
- Belt Drive
  
  206
Engine

210
- Engine Removal
  
  213
  - Installing the Shift Pedal Assembly
    217
  - Checking the Oil Cooler
    219
  - Removing the Engine
    224
  - Installing the Engine
    224
- Camshafts
  
  226
  - Removing the Cylinder Head Covers
    233
  - Removing the Rocker Arms, Push Rods and Valve Lifters
    233
  - Removing the Camshafts
    233
  - Checking the Camshafts
    235
  - Checking the Rocker Arms and Rocker Arm Shafts
    236
  - Checking the Rocker Arm Bases
    237
  - Checking the Push Rods
    237
  - Checking the Valve Lifters and Valve Lifter Cases
    237
  - Checking the Push Rod Cover
    238
  - Checking the Decompression System
    238
  - Checking the Decompression Cam Spring
    238
  - Checking the Oil Delivery Pipe
    239
  - Installing the Camshafts
    239
  - Bleeding a Valve Lifter
    241
  - Installing the Valve Lifters
    242
  - Installing the Rocker Arms and Push Rods
    243
  - Installing the Cylinder Head Covers
    244
  - Installing the Shift Pedal Assembly
    244
- Cylinder Heads
  
  245
  - Removing the Cylinder Heads
    247
  - Checking the Cylinder Heads
    247
  - Checking the Oil Pipe
    247
  - Installing the Cylinder Heads
    248
- Valves and Valve Springs
  
  251
  - Removing the Valves
    251
  - Checking the Valves and Valve Guides
    251
  - Checking the Valve Seats
    253
  - Checking the Valve Springs
    254
  - Installing the Valves
    255
- Cylinders and Pistons
  
  258
  - Removing the Piston
    258
  - Checking the Cylinders and Pistons
    258
  - Checking the Piston Rings
    259
  - Checking the Piston Pins
    260
  - Installing the Pistons and Cylinders
    260
- Clutch
  
  262
  - Removing the Clutch
    272
  - Removing the Primary Drive Gear
    272
  - Removing the Left Balancer Drive Gear
    272
  - Checking the Friction Plates
    273
  - Checking the Clutch Plates
    273
  - Checking the Clutch Spring Plate
    273
  - Checking the Clutch Housing
    274
  - Checking the Clutch Boss
    274
  - Checking the Pressure Plate
    274
  - Checking the Clutch Push Rods
    274
  - Checking the Primary Drive Gear
    274
  - Checking the Primary Driven Gear
    274
  - Checking the Left Balancer Gears
    274
  - Installing the Left Balancer Drive Gear
    275
  - Installing the Primary Drive Gear
    276
  - Installing the Clutch
    277
  - Disassembling the Clutch Master Cylinder
    278
  - Checking the Clutch Master Cylinder
    278
  - Assembling the Clutch Master Cylinder
    279
  - Installing the Clutch Master Cylinder
    279
  - Removing the Clutch Release Cylinder
    280
  - Checking the Clutch Release Cylinder
    280
  - Assembling the Clutch Release Cylinder
    280
  - Installing the Clutch Release Cylinder
    281
- Shift Shaft
  
  283
  - Checking the Shift Shaft
    283
  - Checking the Stopper Lever
    283
  - Installing the Shift Shaft
    283
- Generator and Starter Clutch
  
  284
  - Removing the Generator
    286
  - Removing the Starter Clutch
    286
  - Checking the Starter Clutch
    286
  - Checking the Torque Limiter
    287
  - Installing the Starter Clutch
    287
  - Installing the Generator
    287
- Electric Starter
  
  289
  - Checking the Starter Motor
    291
  - Assembling the Starter Motor
    292
- Transfer Gear Case
  
  293
  - Removing the Middle Driven Shaft
    298
  - Checking the Middle Drive
    298
  - Checking the Oil Strainer
    298
  - Checking the Transfer Gear Oil Pump
    298
  - Checking the Oil Pipes
    299
  - Assembling the Transfer Gear Oil Pump
    299
  - Installing the Transfer Gear Case
    299
- Crankcase
  
  301
  - Disassembling the Crankcase
    304
  - Checking the Crankcase
    304
  - Checking the Bearings and Oil Seal
    304
  - Checking the Oil Delivery Pipe and Oil Pipe
    304
  - Checking the Oil Strainers
    304
  - Checking the Engine Oil Pump Driven Gear
    305
  - Installing the Bearing Retainers
    305
  - Assembling the Crankcase
    305
- Oil Pump
  
  307
  - Checking the Oil Pump
    310
  - Checking the Relief Valve
    310
  - Checking the Ball Spring and Relief Valve Spring
    310
  - Checking the Oil Strainer
    311
  - Assembling the Oil Pump
    311
  - Installing the Oil Pump
    312
- Crankshaft
  
  313
- Transmission
  
  319
Fuel System

326
- Fuel Tank
  327
- Fuel Tank
  
  329
  - Removing the Fuel Tank
    329
  - Removing the Fuel Pump
    329
  - Checking the Fuel Pump Body
    330
  - Checking the Fuel Pump Operation
    330
  - Installing the Fuel Pump
    330
  - Installing the Fuel Tank
    330
- Throttle Bodies
  
  336
  - Removing the Fuel Hose
    337
  - Checking the Injectors
    337
  - Checking the Throttle Bodies
    337
  - Checking the Rollover Valves
    337
  - Checking the Pressure Regulator
    337
  - Checking the Pressure Regulator Operation
    337
  - Installing the Fuel Pipe
    338
  - Installing the Fuel Hose
    339
- Isc (Idle Speed Control) Unit
  
  340
  - Checking the Isc (Idle Speed Control) System
    341
Electrical System

342
- Ignition System
  
  345
  - Circuit Diagram
    345
  - Engine Stopping Due to Sidestand Operation
    347
  - Troubleshooting
    348
- Electric Starting System
  
  351
  - Circuit Diagram
    351
  - Starting Circuit Cut-Off System Operation
    353
  - Troubleshooting
    355
- Charging System
  
  357
  - Circuit Diagram
    357
  - Troubleshooting
    359
- Lighting System
  
  361
  - Circuit Diagram
    361
  - Troubleshooting
    363
- Signaling System
  
  365
  - Circuit Diagram
    365
  - Troubleshooting
    367
- Fuel Injection System
  
  371
  - Circuit Diagram
    371
  - Ecu Self-Diagnostic Function
    373
  - Self-Diagnostic Function Table
    374
  - Troubleshooting Method
    376
  - Diagnostic Mode
    377
  - Troubleshooting Details
    384
- Fuel Pump System
  
  407
  - Circuit Diagram
    407
  - Troubleshooting
    409
- Electrical Components
  
  411
  - Checking the Switches
    415
  - Checking the Bulbs and Bulb Sockets
    418
  - Checking the Fuses
    419
  - Checking and Charging the Battery
    420
  - Checking the Relays
    423
  - Checking the Turn Signal Relay
    424
  - Checking the Diodes
    425
  - Checking the Ignition Spark Gap
    426
  - Checking the Spark Plug Caps
    427
  - Checking the Ignition Coils
    427
  - Checking the Crankshaft Position Sensor
    428
  - Checking the Lean Angle Sensor
    428
  - Checking the Starter Motor Operation
    429
  - Checking the Stator Coil
    429
  - Checking the Rectifier/Regulator
    429
  - Checking the Horns
    430
  - Checking the Engine Temperature Sensor
    431
  - Checking the Fuel Sender (Fuel Tank)
    431
  - Checking the Fuel Sender (Fuel Pump)
    432
  - Checking the Fuel Level Warning Light
    432
  - Checking the Speed Sensor
    432
  - Checking the Throttle Position Sensor
    433
  - Checking the Fuel Pump
    433
  - Checking the Exup Servo Motor
    434
  - Checking the Intake Air Pressure Sensor
    434
  - Checking the Air Temperature Sensor
    434
Troubleshooting

436
- General Information
  437
- Incorrect Engine Idling Speed
  437
- Starting Failures
  437
- Troubleshooting
  437
- Faulty Clutch
  438
- Faulty Gear Shifting
  438
- Jumps out of Gear
  438
- Poor Medium and High-Speed Performance
  438
- Shift Pedal Does Not Move
  438
- Faulty Front Fork Legs
  439
- Overheating
  439
- Poor Braking Performance
  439
- Unstable Handling
  439
- Faulty Lighting or Signaling System
  440
  - Wiring Diagram
    442

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