Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 2

CHECKING THE CONNECTIONS

1-10

EAS20250

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for 
stains, rust, moisture, etc.
1. Disconnect:

• Lead
• Coupler
• Connector

2. Check:

• Lead
• Coupler
• Connector

Moisture 

→

 Dry with an air blower.

Rust/stains 

→

 Connect and disconnect sev-

eral times.

3. Check:

• All connections

Loose connection 

→

 Connect properly.

NOTE:

If the pin “1” on the terminal is flattened, bend it 
up.

4. Connect:

• Lead
• Coupler
• Connector

NOTE:

Make sure all connections are tight.

5. Check:

• Continuity

(with the pocket tester)

NOTE:

• If there is no continuity, clean the terminals.
• When checking the wire harness, perform 

steps (1) to (3).

• As a quick remedy, use a contact revitalizer 

available at most part stores.

 

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

SPECIAL TOOLS

1-11

EAS20260

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only 
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools 
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.

NOTE:

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.

Tool name/Tool No.

Illustration

Reference 

pages

Pocket tester
90890-03112
Analog pocket tester
YU-03112-C

1-10, 5-79, 
7-73, 7-74, 
7-75, 7-79, 
7-80, 7-81, 
7-82, 7-83, 
7-84, 7-85, 
7-86, 7-87, 
7-88, 7-89, 
7-90, 7-91

Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9

3-6, 5-61

Tappet adjusting tool (4 mm)
90890-04133
Valve adjustment wrench 3 mm & 4 mm
YM-08035-A

3-6, 3-7

Vacuum gauge
90890-03094
Carburetor synchronizer
YU-44456

3-7

YU-44456

SPECIAL TOOLS

1-12

Timing light
90890-03141
Inductive clamp timing light
YU-03141

3-10

Oil filter wrench
90890-01426
YU-38411

3-12

Belt tension gauge
90890-03170
Rear drive belt tension gauge
YM-03170

3-24

Steering nut wrench
90890-01403
Spanner wrench
YU-33975

3-26, 4-71

Damper rod holder
90890-01460

4-64, 4-66

T-handle
90890-01326
T-handle 3/8" drive 60 cm long
YM-01326

4-64, 4-66

Fork seal driver
90890-01442
Adjustable fork seal driver (36–46 mm)
YM-01442

4-66, 4-67

Pivot shaft wrench
90890-01485
Frame mount insert wrench
YM-01485

5-12

Valve spring compressor
90890-04019
YM-04019

5-39, 5-44

Tool name/Tool No.

Illustration

Reference 

pages

SPECIAL TOOLS

1-13

Valve guide remover (ø6)
90890-04064
Valve guide remover (6.0 mm)
YM-04064-A

5-40

Valve guide installer (ø6)
90890-04065
Valve guide installer (6.0 mm)
YM-04065-A

5-40

Valve guide reamer (ø6)
90890-04066
Valve guide reamer (6.0 mm)
YM-04066

5-40

Piston pin puller set
90890-01304
Piston pin puller
YU-01304

5-46

Universal clutch holder
90890-04086
YM-91042

5-60, 5-65

Sheave holder
90890-01701
Primary clutch holder
YS-01880-A

5-60, 5-64, 
5-74, 5-75

Yamaha bond No. 1215
90890-85505
(Three Bond No.1215

®

)

5-66, 5-76, 
5-93

Tool name/Tool No.

Illustration

Reference 

pages

YU-01304

SPECIAL TOOLS

1-14

Rotor puller
90890-01080
Stator rotor puller
YM-01080-A

5-74

Vacuum/pressure pump gauge set
90890-06756

6-12

Pressure gauge
90890-03153

6-12

Fuel pressure adapter
90890-03176
YM-03176

6-12

Digital circuit tester
90890-03174
Model 88 Multimeter with tachometer
YU-A1927

6-12

Ignition checker
90890-06754
Opama pet-4000 spark checker
YM-34487

7-83

Tool name/Tool No.

Illustration

Reference 

pages

SPECIAL TOOLS

1-15

2

SPECIFICATIONS

GENERAL SPECIFICATIONS

........................................................................ 2-1

ENGINE SPECIFICATIONS

............................................................................ 2-2

CHASSIS SPECIFICATIONS

........................................................................ 2-10

ELECTRICAL SPECIFICATIONS

................................................................. 2-13

TIGHTENING TORQUES

.............................................................................. 2-16

GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-16
ENGINE TIGHTENING TORQUES......................................................... 2-17
CHASSIS TIGHTENING TORQUES....................................................... 2-22

LUBRICATION POINTS AND LUBRICANT TYPES

.................................... 2-27

ENGINE .................................................................................................. 2-27
CHASSIS ................................................................................................ 2-29

LUBRICATION SYSTEM CHART AND DIAGRAMS

................................... 2-31

ENGINE OIL LUBRICATION CHART ..................................................... 2-31
LUBRICATION DIAGRAMS .................................................................... 2-33

CABLE ROUTING

......................................................................................... 2-45

GENERAL SPECIFICATIONS

2-1

EAS20280

GENERAL SPECIFICATIONS

Model

Model

XV19SW 1D74 (USA)
XV19SW 1D76 (CDN)
XV19SWC 1D75 (California)
XV19W 4D45 (USA)
XV19W 4D47 (CDN)
XV19WC 4D46 (California)
XV19MW 4D54 (USA)
XV19MW 4D56 (CDN)
XV19MWC 4D55 (California)
XV19CTSW 2C54 (USA)
XV19CTSW 2C56 (CDN)
XV19CTSWC 2C55 (California)
XV19CTW 4P04 (USA)
XV19CTW 4P06 (CDN)
XV19CTWC 4P05 (California)
XV19CTMW 4P14 (USA)
XV19CTMW 4P16 (CDN)
XV19CTMWC 4P15 (California)

Dimensions

Overall length

2580 mm (101.6 in)

Overall width

1100 mm (43.3 in)

Overall height

XV19S(C)/XV19(C)/XV19M(C):
1100 mm (43.3 in)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
1515 mm (59.6 in)

Seat height

735 mm (28.9 in)

Wheelbase

1715 mm (67.5 in)

Ground clearance

155 mm (6.10 in)

Minimum turning radius

3480 mm (137.0 in)

Weight

With oil and fuel

XV19S(C)/XV19(C)/XV19M(C):
340.0 kg (750 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
364.0 kg (802 lb)

Maximum load

XV19S(C)/XV19(C)/XV19M(C):
210 kg (463 lb)
XV19CTS(C)/XV19CT(C)/XV19CTM(C):
186 kg (410 lb)

ENGINE SPECIFICATIONS

2-2

EAS20290

ENGINE SPECIFICATIONS

Engine

Engine type

Air cooled 4-stroke, OHV

Displacement

1854.0 cm³

Cylinder arrangement

V-type 2-cylinder

Bore 

×

 stroke

100.0 

×

 118.0 mm (3.94 

×

 4.65 in)

Compression ratio

9.48 :1

Starting system

Electric starter

Fuel

Recommended fuel

Premium unleaded gasoline only

Fuel tank capacity

17.0 L (4.49 US gal) (3.74 Imp.gal)

Fuel reserve amount

3.0 L (0.79 US gal) (0.66 Imp.gal)

Engine oil

Lubrication system

Dry sump

Type

YAMALUBE 4 (20W40) or SAE20W40

Recommended engine oil grade

API service SG type or higher, JASO standard 
MA

Engine oil quantity

Total amount

5.20 L (5.50 US qt) (4.58 Imp.qt)

Engine

3.2 L (3.38 US qt) (2.82 Imp.qt)

Oil tank

2.0 L (2.11 US qt) (1.76 Imp.qt)

Without oil filter cartridge replacement

4.10 L (4.33 US qt) (3.61 Imp.qt)

With oil filter cartridge replacement

4.90 L (5.18 US qt) (4.31 Imp.qt)

Oil pressure (hot)

60.0 kPa/900 r/min (8.7 psi/900 r/min) (0.60 
kgf/cm²/900 r/min)

Transfer gear oil

Type

SAE80 API GL-4 Hypoid gear oil

Quantity (disassembled)

0.60 L (0.63 US qt) (0.53 Imp.qt)

Quantity

0.55 L (0.58 US qt) (0.48 Imp.qt)

Oil filter

Oil filter type

Cartridge (paper)

Oil pump

Oil pump type

Trochoid

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

0.09–0.19 mm (0.0035–0.0075 in)

Limit

0.26 mm (0.0102 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)

Bypass valve opening pressure

80.0–120.0 kPa (11.6–17.4 psi) (0.80–1.20 
kgf/cm²)

Relief valve operating pressure

600.0 kPa (87.0 psi) (6.00 kgf/cm²)

Transfer gear oil pump

Oil pump type

Trochoid

ENGINE SPECIFICATIONS

2-3

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)

Spark plug (s)

Manufacturer/model

NGK/DPR8EA-9

Manufacturer/model

DENSO/X24EPR-U9

Spark plug gap

0.8–0.9 mm (0.031–0.035 in)

Cylinder head

Volume

80.90–84.90 cm³ (4.94–5.18 cu.in)

Warpage limit

0.03 mm (0.0012 in)

Camshaft

Drive system

Gear drive

Crankcase hole inside diameter

25.000–25.021 mm (0.9843–0.9851 in)

Camshaft journal diameter (crankcase side)

24.957–24.980 mm (0.9826–0.9835 in)

Camshaft to crankcase clearance

0.020–0.064 mm (0.0008–0.0025 in)

Camshaft cover hole inside diameter

28.000–28.021 mm (1.1024–1.1032 in)

Camshaft journal diameter (camshaft cover side)

27.957–27.980 mm (1.1007–1.1016 in)

Camshaft to camshaft cover clearance

0.020–0.064 mm (0.0008–0.0025 in)

Camshaft lobe dimensions

Intake A

42.532–42.632 mm (1.6745–1.6784 in)

Limit

42.432 mm (1.6705 in)

Intake B

35.950–36.050 mm (1.4154–1.4193 in)

Limit

35.850 mm (1.4114 in)

Exhaust A

42.530–42.630 mm (1.6744–1.6783 in) (cylinder 
#1)
42.531–42.631 mm (1.6744–1.6784 in) (cylinder 
#2)

Limit

42.430 mm (1.6705 in) (cylinder #1)
42.431 mm (1.6705 in) (cylinder #2)

Exhaust B

35.950–36.050 mm (1.4154–1.4193 in)

Limit

35.850 mm (1.4114 in)

ENGINE SPECIFICATIONS

2-4

Rocker arm/rocker arm shaft

Rocker arm inside diameter

18.000–18.018 mm (0.7087–0.7094 in)

Limit

18.036 mm (0.7101 in)

Rocker arm shaft outside diameter

17.976–17.991 mm (0.7077–0.7083 in)

Rocker-arm-to-rocker-arm-shaft clearance

0.009–0.042 mm (0.0004–0.0017 in)

Limit

0.080 mm (0.0032 in)

Valve, valve seat, valve guide

Valve clearance (cold)

Intake

0.00–0.04 mm (0.0000–0.0016 in)

Exhaust

0.00–0.04 mm (0.0000–0.0016 in)

Valve dimensions

Valve head diameter A (intake)

35.90–36.10 mm (1.4134–1.4213 in)

Valve head diameter A (exhaust)

30.90–31.10 mm (1.2165–1.2244 in)

Valve seat width C (intake)

1.10–1.30 mm (0.0433–0.0512 in)

Limit

2.0 mm (0.08 in)

Valve seat width C (exhaust)

1.10–1.30 mm (0.0433–0.0512 in)

Limit

2.0 mm (0.08 in)

Valve margin thickness D (intake)

1.15–1.45 mm (0.0453–0.0571 in)

Limit

0.4 mm (0.02 in)

Valve margin thickness D (exhaust)

1.15–1.45 mm (0.0453–0.0571 in)

Limit

0.4 mm (0.02 in)

Valve stem diameter (intake)

5.975–5.990 mm (0.2352–0.2358 in)

Limit

5.945 mm (0.2341 in)

Valve stem diameter (exhaust)

5.960–5.975 mm (0.2346–0.2352 in)

Limit

5.920 mm (0.2331 in)

Valve guide inside diameter (intake)

6.000–6.012 mm (0.2362–0.2367 in)

Limit

6.050 mm (0.2382 in)

A

B

A

C

D

ENGINE SPECIFICATIONS

2-5

Valve guide inside diameter (exhaust)

6.000–6.012 mm (0.2362–0.2367 in)

Limit

6.050 mm (0.2382 in)

Valve-stem-to-valve-guide clearance (intake)

0.010–0.037 mm (0.0004–0.0015 in)

Limit

0.080 mm (0.0032 in)

Valve-stem-to-valve-guide clearance (exhaust)

0.025–0.052 mm (0.0010–0.0020 in)

Limit

0.100 mm (0.0039 in)

Valve stem runout

0.010 mm (0.0004 in)

Valve spring

Free length (intake)

46.71 mm (1.84 in)

Limit

44.71 mm (1.76 in)

Free length (exhaust)

46.71 mm (1.84 in)

Limit

44.71 mm (1.76 in)

Installed length (intake)

32.66 mm (1.29 in)

Installed length (exhaust)

32.66 mm (1.29 in)

Spring rate K1 (intake)

16.58 N/mm (94.67 lb/in) (1.69 kgf/mm)

Spring rate K2 (intake)

21.98 N/mm (125.51 lb/in) (2.24 kgf/mm)

Spring rate K1 (exhaust)

16.58 N/mm (94.67 lb/in) (1.69 kgf/mm)

Spring rate K2 (exhaust)

21.98 N/mm (125.51 lb/in) (2.24 kgf/mm)

Installed compression spring force (intake)

217.00–249.00 N (48.78–55.98 lb) (22.13–
25.39 kgf)

Installed compression spring force (exhaust)

217.00–249.00 N (48.78–55.98 lb) (22.13–
25.39 kgf)

Spring tilt (intake)

2.5 °/2.0 mm

Spring tilt (exhaust)

2.5 °/2.0 mm

Winding direction (intake)

Clockwise

Winding direction (exhaust)

Clockwise

Valve lifter

Valve lifter outside diameter (intake)

22.962–22.974 mm (0.9040–0.9045 in)

Valve lifter outside diameter (exhaust)

22.962–22.974 mm (0.9040–0.9045 in)

Valve lifter hole inside diameter (intake)

23.000–23.021 mm (0.9055–0.9063 in)

Valve lifter hole inside diameter (exhaust)

23.000–23.021 mm (0.9055–0.9063 in)

Valve-lifter-to-valve-lifter-hole clearance

0.026–0.059 mm (0.0010–0.0023 in)

Valve push rod

Valve push rod 1 length

286.5 mm (11.280 in)

Valve push rod 2 length

288.5 mm (11.358 in)

ENGINE SPECIFICATIONS

2-6

Valve push rod runout

0.3 mm (0.012 in)

Cylinder

Bore

100.000–100.010 mm (3.9370–3.9374 in)

Taper limit

0.050 mm (0.0020 in)

Out of round limit

0.050 mm (0.0020 in)

Piston

Piston-to-cylinder clearance

0.025–0.050 mm (0.0010–0.0020 in)

Limit

0.15 mm (0.0059 in)

Diameter D

99.960–99.975 mm (3.9354–3.9360 in)

Height H

10.0 mm (0.39 in)

Offset

0.50 mm (0.0197 in)

Piston pin bore inside diameter

23.004–23.015 mm (0.9057–0.9061 in)

Limit

23.045 mm (0.9073 in)

Piston pin outside diameter

22.991–23.000 mm (0.9052–0.9055 in)

Limit

22.971 mm (0.9044 in)

Piston-pin-to-piston-pin-bore clearance

0.004–0.024 mm (0.00016–0.00094 in)

Limit

0.074 mm (0.00291 in)

Piston ring

Top ring

Ring type

Barrel

Dimensions (B 

×

 T)

1.20 

×

 3.80 mm (0.05 

×

 0.15 in)

End gap (installed)

0.20–0.35 mm (0.0079–0.0138 in)

Limit

0.55 mm (0.0217 in)

Ring side clearance

0.030–0.080 mm (0.0012–0.0032 in)

Limit

0.120 mm (0.0047 in)

2nd ring

Ring type

Taper

Dimensions (B 

×

 T)

1.20 

×

 4.00 mm (0.05 

×

 0.16 in)

End gap (installed)

0.45–0.60 mm (0.0177–0.0236 in)

Limit

0.95 mm (0.0374 in)

Ring side clearance

0.030–0.070 mm (0.0012–0.0028 in)

Limit

0.120 mm (0.0047 in)

H

D

T

B

B

T

ENGINE SPECIFICATIONS

2-7

Oil ring

Dimensions (B 

×

 T)

2.50 

×

 3.40 mm (0.10 

×

 0.13 in)

End gap (installed)

0.20–0.70 mm (0.0079–0.0276 in)

Connecting rod

Oil clearance (using plastigauge

®

)

0.050–0.074 mm (0.0020–0.0029 in)

Bearing color code

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

Crankshaft

Width A

105.80–106.20 mm (4.165–4.181 in)

Runout limit C

0.040 mm (0.0016 in)

Big end side clearance D

0.320–0.474 mm (0.0126–0.0187 in)

Big end radial clearance E

0.037–0.074 mm (0.0015–0.0029 in)

Limit

0.09 mm (0.0035 in)

Journal oil clearance (using plastigauge

®

)

0.030–0.060 mm (0.0012–0.0024 in)

Limit

0.10 mm (0.0039 in)

Clutch

Clutch type

Wet, multiple-disc

Clutch release method

Hydraulic inner push

Operation

Left hand operation

Friction plate 1, 3 thickness

2.90–3.10 mm (0.114–0.122 in)

Wear limit

2.80 mm (0.110 in)

Plate quantity

10 pcs

Friction plate 2 thickness

2.92–3.08 mm (0.115–0.121 in)

Wear limit

2.82 mm (0.111 in)

Plate quantity

1 pcs

Clutch plate thickness

1.90–2.10 mm (0.075–0.083 in)

Plate quantity

10 pcs

Warpage limit

0.20 mm (0.0079 in)

Clutch spring free length

6.78 mm (0.27 in)

Minimum length

6.28 mm (0.25 in)

Spring quantity

1 pcs

Clutch housing thrust clearance

0.100–0.110 mm (0.0039–0.0043 in)

Clutch housing radial clearance

0.020–0.066 mm (0.0008–0.0026 in)

Transmission

Transmission type

Constant mesh 5-speed

B

T

ENGINE SPECIFICATIONS

2-8

Primary reduction system

Spur gear

Primary reduction ratio

72/51 (1.412)

Secondary reduction system

Belt drive

Secondary reduction ratio

70/31 (2.258)

Operation

Left foot operation

Gear ratio

1st

38/16 (2.375)

2nd

33/21 (1.571)

3rd

29/25 (1.160)

4th

26/28 (0.929)

5th

24/30 (0.800)

Main axle runout limit

0.08 mm (0.0032 in)

Drive axle runout limit

0.08 mm (0.0032 in)

Shifting mechanism

Shift mechanism type

Guide bar

Shift fork guide bar bending limit

0.025 mm (0.0010 in)

Shift fork thickness

6.26–6.39 mm (0.2465–0.2516 in)

Air filter

Air filter element

Oil-coated paper element

Fuel pump

Pump type

Electrical

Model/manufacturer

1D7/MITSUBISHI

Maximum consumption amperage

5.5 A

Output pressure

441.0–637.0 kPa (63.9–92.4 psi) (4.41–6.37 
kgf/cm²)

Fuel injection

Model/quantity

INP-101/2

Manufacturer

NIPPON INJECTOR

Throttle body

Type/quantity

AC43/2

Manufacturer

MIKUNI

ID mark

XV19M/XV19S/XV19/XV19CTM/
XV19CTS/XV19CT:
1D71 00
XV19MC/XV19SC/XV19C/XV19CTMC/
XV19CTSC/XV19CTC:
1D72 10

Throttle valve size

#100

Throttle position sensor

Resistance

4.0–6.0 k

Ω

/blue-black

Output voltage (at idle)

0.63–0.73 V

Fuel injection sensor

Crankshaft position sensor resistance

248–372 

Ω

Intake air pressure sensor output voltage

3.75–4.25 V

Engine temperature sensor resistance

0.90–1.10 k

Ω

 at 100 °C (212 °F)

ENGINE SPECIFICATIONS

2-9

Idling condition

Engine idling speed

850–950 r/min

Intake vacuum

31.3–35.3 kPa (9.3–10.4 inHg) (235–265 
mmHg)

Oil temperature

80.0–90.0 °C (176.00–194.00 °F)

Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)