Yamaha XV19MX(C) Manuals

Manuals and User Guides for Yamaha XV19MX(C). We have 1 Yamaha XV19MX(C) manual available for free PDF download: Service Manual

Yamaha XV19MX(C) Service Manual

Yamaha XV19MX(C) Service Manual (494 pages)

Brand: Yamaha | Category: Motorcycle | Size: 30.78 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- Symbols
  5
- General Information
  9
  - Identification
    10
  - Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    INSTRUMENT FUNCTIONS (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
    13
    
    INSTRUMENT FUNCTIONS (for XV19CS(C)/ XV19C(C))
    16
  - Important Information
    20
    
    Preparation for Removal and Disassembly
    20
    
    Replacement Parts
    20
    
    Gaskets, Oil Seals and O-Rings
    20
    
    Lock Washers/Plates and Cotter Pins
    20
    
    Bearings and Oil Seals
    21
    
    Circlips
    21
  - Checking the Connections
    22
  - Special Tools
    23
Specifications

27
- General Specifications
  28
- Engine Specifications
  30
- Chassis Specifications
  38
- Electrical Specifications
  43
- Tightening Torques
  47
- Lubrication Points and Lubricant Types
  60
  - Engine
    60
  - Chassis
    62
- Lubrication System Chart and Diagrams
  64
  - Engine Oil Lubrication Chart
    64
  - Lubrication Diagrams
    66
- CABLE ROUTING (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
  78
- CABLE ROUTING (for XV19CS(C)/ XV19C(C))
  94
Periodic Checks and Adjustments

111
- Periodic Maintenance
  
  114
- Engine
  
  117
  - Adjusting the Valve Clearance
    117
    
    Synchronizing the Throttle Bodies
    120
    
    Adjusting the Throttle Cable Free Play
    121
    
    Checking the Spark Plugs
    122
    
    Checking the Ignition Timing
    123
    
    Checking the Engine Oil Level
    124
    
    Changing the Engine Oil
    124
    
    Checking the Transfer Gear Oil Level
    126
    
    Changing the Transfer Gear Oil
    127
    
    Checking the Clutch Fluid Level
    127
    
    Bleeding the Hydraulic Clutch System
    128
    
    Replacing the Air Filter Element
    128
    
    Checking the Throttle Body Joints
    129
    
    Checking the Fuel Line
    129
    
    Checking the Cylinder Head Breather Hose
    130
    
    Checking the Oil Tank Breather Hose
    130
    
    CHECKING the EXHAUST SYSTEM (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
    130
    
    CHECKING the EXHAUST SYSTEM (for XV19CS(C)/ XV19C(C))
    131
    
    CHECKING the CANISTER (for California Only) (for XV19SC/ XV19MC/ XV19CTSC/ XV19CTMC)
    132
    
    CHECKING the CANISTER (for California Only) (for XV19CSC/ XV19CC)
    132
    
    Adjusting the Exup Cables
    132
- Chassis
  
  134
  - Adjusting the Rear Disc Brake
    134
  - Checking the Brake Fluid Level
    134
  - Checking the Front Brake Pads
    135
  - Checking the Rear Brake Pads
    135
  - Checking the Front Brake Hoses
    136
  - Checking the Rear Brake Hoses
    136
  - Adjusting the Rear Brake Light Switch
    136
  - Bleeding the Hydraulic Brake System
    137
  - Adjusting the Shift Pedal
    138
  - Adjusting the Drive Belt Slack
    139
  - Checking and Adjusting the Steering Head
    140
  - Checking the Front Fork
    141
  - Adjusting the Rear Shock Absorber Assembly
    141
  - Checking the Tires
    142
  - Checking the Wheels
    144
  - Checking and Lubricating the Cables
    144
  - Lubricating the Levers
    145
  - Lubricating the Pedals
    145
  - Lubricating the Sidestand
    145
  - Lubricating the Rear Suspension
    145
- Electrical System
  
  146
  - Checking and Charging the Battery
    146
    
    Checking the Fuses
    146
    
    REPLACING the HEADLIGHT BULBS (for XV19S(C)/ XV19M(C)/ XV19CTS(C)/ XV19CTM(C))
    146
    
    REPLACING the HEADLIGHT BULB (for XV19CS(C)/ XV19C(C))
    147
    
    Adjusting the Headlight Beams
    148
Chassis

151
- General Chassis
  
  154
  - Removing the Windshield
    155
  - Assembling the Windshield
    155
  - Installing the Windshield
    155
  - Removing the Backrest
    158
  - Assembling the Backrest
    158
  - Installing the Backrest
    158
  - Checking the Sidebag Bracket Spring Nuts
    161
- Front Wheel
  
  171
  - Removing the Front Wheel
    175
  - Disassembling the Front Wheel
    175
  - Checking the Front Wheel
    175
  - Assembling the Front Wheel
    176
  - Adjusting the Front Wheel Static Balance
    176
  - Installing the Front Wheel (Front Brake Discs)
    177
- Rear Wheel
  
  180
  - Removing the Rear Wheel (Disc)
    185
  - Disassembling the Rear Wheel
    185
  - Checking the Rear Wheel
    185
  - Checking the Rear Brake Caliper Bracket
    185
  - Checking the Rear Wheel Drive Hub
    186
  - Checking and Replacing the Rear Wheel Pulley
    186
  - Assembling the Rear Wheel
    186
  - Adjusting the Rear Wheel Static Balance
    186
  - Installing the Rear Wheel (Disc)
    186
- Front Brake
  
  188
- Rear Brake
  
  200
  - Introduction
    206
  - Checking the Rear Brake Disc
    206
  - Replacing the Rear Brake Pads
    206
  - Removing the Rear Brake Caliper
    207
  - Disassembling the Rear Brake Caliper
    207
  - Checking the Rear Brake Caliper
    208
  - Assembling the Rear Brake Caliper
    208
  - Installing the Rear Brake Caliper
    208
  - Removing the Rear Brake Master Cylinder
    209
  - Checking the Rear Brake Master Cylinder
    210
  - Assembling the Rear Brake Master Cylinder
    210
  - Installing the Rear Brake Master Cylinder
    210
- Handlebar
  
  212
  - Removing the Handlebar
    216
  - Checking the Handlebar
    216
  - Installing the Handlebar
    216
- Front Fork
  
  219
- Steering Head
  
  230
- Rear Shock Absorber Assembly and Swingarm
  
  236
Engine

247
- Engine Removal
  
  250
- Camshafts
  
  266
- Cylinder Heads
  
  285
  - Removing the Cylinder Heads
    287
  - Checking the Cylinder Heads
    287
  - Checking the Oil Pipe
    287
  - Installing the Cylinder Heads
    288
- Valves and Valve Springs
  
  291
  - Removing the Valves
    291
  - Checking the Valves and Valve Guides
    291
  - Checking the Valve Seats
    293
  - Checking the Valve Springs
    294
  - Installing the Valves
    295
- Cylinders and Pistons
  
  298
  - Removing the Piston
    298
  - Checking the Cylinders and Pistons
    298
  - Checking the Piston Rings
    299
  - Checking the Piston Pins
    300
  - Installing the Pistons and Cylinders
    300
- Clutch
  
  302
  - Removing the Clutch
    313
  - Removing the Primary Drive Gear
    313
  - Removing the Left Balancer Drive Gear
    313
  - Checking the Friction Plates
    314
  - Checking the Clutch Plates
    314
  - Checking the Clutch Spring Plate
    314
  - Checking the Clutch Housing
    315
  - Checking the Clutch Boss
    315
  - Checking the Pressure Plate
    315
  - Checking the Clutch Push Rods
    315
  - Checking the Primary Drive Gear
    315
  - Checking the Primary Driven Gear
    315
  - Checking the Left Balancer Gears
    315
  - Installing the Left Balancer Drive Gear
    316
  - Installing the Primary Drive Gear
    317
  - Installing the Clutch
    318
  - Disassembling the Clutch Master Cylinder
    319
  - Checking the Clutch Master Cylinder
    319
  - Assembling the Clutch Master Cylinder
    320
  - Installing the Clutch Master Cylinder
    320
  - Removing the Clutch Release Cylinder
    321
  - Checking the Clutch Release Cylinder
    321
  - Assembling the Clutch Release Cylinder
    322
  - Installing the Clutch Release Cylinder
    322
- Shift Shaft
  
  324
  - Checking the Shift Shaft
    325
  - Checking the Stopper Lever
    325
  - Installing the Shift Shaft
    325
- Generator and Starter Clutch
  
  326
  - Removing the Generator
    328
  - Removing the Starter Clutch
    328
  - Checking the Starter Clutch
    328
  - Checking the Torque Limiter
    329
  - Installing the Starter Clutch
    329
  - Installing the Generator
    329
- Electric Starter
  
  331
  - Checking the Starter Motor
    333
  - Assembling the Starter Motor
    334
- Transfer Gear Case
  
  335
  - Removing the Middle Driven Shaft
    340
  - Checking the Middle Drive
    340
  - Checking the Oil Strainer
    340
  - Checking the Transfer Gear Oil Pump
    340
  - Checking the Oil Pipes
    341
  - Assembling the Transfer Gear Oil Pump
    341
  - Installing the Transfer Gear Case
    341
- Crankcase
  
  343
  - Disassembling the Crankcase
    346
  - Checking the Crankcase
    346
  - Checking the Bearings and Oil Seal
    346
  - Checking the Oil Delivery Pipe and Oil Pipe
    346
  - Checking the Oil Strainers
    346
  - Checking the Engine Oil Pump Driven Gear
    346
  - Installing the Bearing Retainers
    347
  - Assembling the Crankcase
    347
- Oil Pump
  
  349
  - Checking the Oil Pump
    352
  - Checking the Relief Valve
    352
  - Checking the Ball Spring and Relief Valve Spring
    352
  - Checking the Oil Strainer
    353
  - Assembling the Oil Pump
    353
  - Installing the Oil Pump
    354
- Crankshaft
  
  356
- Transmission
  
  364
Fuel System

369
- Fuel Tank
  
  373
  - Removing the Fuel Tank
    373
  - Removing the Fuel Pump
    373
  - Checking the Fuel Pump Body
    374
  - Checking the Fuel Pump Operation
    374
  - Installing the Fuel Pump
    374
  - Installing the Fuel Tank
    374
- Throttle Bodies
  
  376
  - Removing the Fuel Hose
    384
  - Checking the Injectors
    384
  - Checking the Throttle Bodies
    384
  - Checking the Rollover Valves
    384
  - Checking the Pressure Regulator
    384
  - Checking the Pressure Regulator Operation
    384
  - Installing the Fuel Pipe
    385
  - Installing the Fuel Hose
    386
- Isc (Idle Speed Control) Unit
  
  387
  - Checking the Isc (Idle Speed Control) System
    388
Electrical System

389
- Ignition System
  
  392
  - Circuit Diagram
    392
  - Engine Stopping Due to Sidestand Operation
    394
  - Troubleshooting
    395
- Electric Starting System
  
  398
  - Circuit Diagram
    398
  - Starting Circuit Cut-Off System Operation
    400
  - Troubleshooting
    402
- Charging System
  
  404
  - Circuit Diagram
    404
  - Troubleshooting
    406
- Lighting System
  
  408
  - Circuit Diagram
    408
  - Troubleshooting
    410
- Signaling System
  
  412
  - Circuit Diagram
    412
  - Troubleshooting
    414
- Fuel Injection System
  
  418
  - Circuit Diagram
    418
  - Ecu Self-Diagnostic Function
    420
  - Self-Diagnostic Function Table
    421
  - Troubleshooting Method
    423
  - Diagnostic Mode
    424
  - Troubleshooting Details
    431
- Fuel Pump System
  
  454
  - Circuit Diagram
    454
    
    Electrical Components
    458
    
    Checking the Switches
    462
  - General Information
    483
    
    Wiring Diagram
    488
  - Troubleshooting
    483

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