Yamaha XV19SW(C), XV19W(C), XV19MW(C), XV19CTSW(C), XV19CTW(C), XV19CTMW(C). Service Manual - part 18

CLUTCH

5-64

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4. Install:

• Generator rotor

Refer to “INSTALLING THE GENERATOR” 
on page 5-75.

5. Install:

• Left balancer drive gear “1”
• Left balancer idle gear “2”
• Left balancer driven gear “3”

NOTE:

• Align the punch mark “a” on the left balancer 

drive gear with the punch mark “b” on the left 
balancer idle gear.

• Align the punch marks “c” on the left balancer 

idle gear with the punch marks “d” on the left 
balancer driven gear.

6. Tighten:

• Left balancer drive gear bolt “1”

NOTE:

While holding the generator rotor “2” with the 
sheave holder “3”, tighten the left balancer drive 
gear bolt.

EAS25230

INSTALLING THE PRIMARY DRIVE GEAR

1. Install:

• Washer
• Straight key
• Primary drive gear
• Crankshaft position sensor rotor “1”
• Spacer
• Primary drive gear bolt “2”

CAUTION:

EC1D71007

The timing marks on the crankshaft position 
sensor rotor must face outside.

NOTE:

• Lubricate the primary drive gear bolt threads 

with engine oil.

• While holding the generator rotor “3” with the 

sheave holder “4”, tighten the primary drive 
gear bolt.

T

 

R

.

 

Left balancer drive gear bolt

40 Nm (4.0 m·kg, 29 ft·lb)

 

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

b

a

2

d

c

1

a

b

3

T

 

R

.

 

Primary drive gear bolt

100 Nm (10.0 m·kg, 72 ft·lb)

 

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

1

2

3

CLUTCH

5-65

EAS25260

INSTALLING THE CLUTCH

1. Install:

• Clutch housing
• Thrust washer

NOTE:

• Lubricate the clutch housing bearings with en-

gine oil.

• Make sure that the primary driven gear teeth 

and primary drive gear teeth mesh correctly.

• Make sure that the primary driven gear teeth 

and oil pump driven gear teeth mesh correctly.

2. Install:

• Clutch boss assembly “1”

NOTE:

• Install the clutch damper spring “2” with the 

“OUTSIDE” mark facing out.

• If the wire circlip “3” has been removed, care-

fully install a new one.

3. Install:

• Clutch boss “1”

• Washer
• Conical spring washer “2”
• Clutch boss nut “3”

NOTE:

• Lubricate the clutch boss nut threads and con-

ical spring washer mating surfaces with engine 
oil.

• Install the conical spring washer “2” with the 

“OUT” mark “a” facing out.

• While holding the clutch boss with the univer-

sal clutch holder “4”, tighten the clutch boss 
nut.

• Stake the clutch boss nut “3” at a cutout “b” in 

the main axle.

4. Lubricate:

• Friction plates
• Clutch plates

(with the recommended lubricant)

5. Install:

• Friction plates 2 “1”
• Clutch plates
• Friction plate 1 “2”

NOTE:

• First, install a friction plate and then alternate 

between a clutch plate and a friction plate.

• Align a projection on each friction plate 2 “1” 

with the “

” mark “a” on the clutch housing 

and align a projection on friction plate 1 “2” with 
the punch mark “b” on the housing.

2

1

3

4

1

2

3

New

T

 

R

.

 

Clutch boss nut

105 Nm (10.5 m·kg, 75 ft·lb)

 

Universal clutch holder

90890-04086
YM-91042

 

Recommended lubricant

Engine oil

1

b

4

3

2

a

CLUTCH

5-66

6. Install:

• Clutch spring plate
• Clutch spring plate retainer

NOTE:

Tighten the clutch spring plate retainer bolts in 
stages and in a crisscross pattern.

7. Apply:

• Sealant

(onto the crankshaft position sensor lead 
grommet)

8. Install:

• Shift arm “1”

NOTE:

Install the shift arm “1” with its slot “a” aligned 
with the mark “b” in end of the shift shaft.

EAS25280

DISASSEMBLING THE CLUTCH MASTER 
CYLINDER

NOTE:

Before disassembling the clutch master cylinder, 
drain the clutch fluid from the entire clutch sys-
tem.

1. Remove:

• Clutch hose union bolt “1”
• Copper washers “2”
• Clutch hose “3”

NOTE:

To collect any remaining clutch fluid, place a 
container under the master cylinder and the end 
of the clutch hose.

ET1D71037

CHECKING THE CLUTCH MASTER 
CYLINDER

1. Check:

• Clutch master cylinder

Damage/scratches/wear 

→

 Replace.

• Clutch fluid delivery passage

(clutch master cylinder body)
Obstruction 

→

 Blow out with compressed air.

2. Check:

• Clutch master cylinder kit

Damage/scratches/wear 

→

 Replace.

3. Check:

• Clutch master cylinder reservoir

Cracks/damage 

→

 Replace.

T

 

R

.

 

Clutch spring plate retainer bolt

8 Nm (0.8 m·kg, 5.8 ft·lb)

 

Yamaha bond No. 1215

90890-85505
(Three Bond No.1215

®

)

T

 

R

.

 

Shift arm bolt

12 Nm (1.2 m·kg, 8.7 ft·lb)

a

b

1

2

a

b

1

b

a

1

2

3

CLUTCH

5-67

• Clutch master cylinder reservoir diaphragm

Damage/wear 

→

 Replace.

4. Check:

• Clutch hose

Cracks/damage/wear 

→

 Replace.

EAS25300

ASSEMBLING THE CLUTCH MASTER 
CYLINDER

WARNING

EW1D71010

• Before installation, all internal clutch com-

ponents must be cleaned and lubricated 
with clean or new clutch fluid.

• Never use solvents on internal clutch com-

ponents.

EAS25310

INSTALLING THE CLUTCH MASTER 
CYLINDER

1. Install:

• Clutch master cylinder “1”
• Clutch master cylinder holder “2”

NOTE:

• Align the end of the clutch lever holder with the 

punch mark “a” on the handlebar.

• First, tighten the rear bolt, then the front bolt.

2. Install:

• Copper washers 
• Clutch hose “1”
• Clutch hose union bolt “2”

WARNING

EW1D71002

Proper clutch hose routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-45.

NOTE:

• Install the clutch hose at 5–25° “a” angle to the 

clutch master cylinder as shown in the illustra-
tion.

• While holding the clutch hose, tighten the 

union bolt.

• Turn the handlebar to the left and right to make 

sure the clutch hose does not touch other parts 
(e.g., wire harness, cables, leads). Correct if 
necessary.

3. Fill:

• Clutch master cylinder reservoir

(with the specified amount of the recom-
mended clutch fluid)

WARNING

EWA13370

• Use only the designated clutch fluid. Other 

clutch fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
clutch performance.

• Refill with the same type of clutch fluid that 

is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.

• When refilling, be careful that water does 

not enter the clutch fluid reservoir. Water 
will significantly lower the boiling point of 
the clutch fluid and could cause vapor lock.

CAUTION:

ECA13420

Clutch fluid may damage painted surfaces or 
plastic parts. Therefore, always clean up any 
spilt clutch fluid immediately.

 

Recommended clutch fluid

Brake fluid DOT 4

T

 

R

.

 

Clutch master cylinder holder 
bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)

T

 

R

.

 

Clutch hose union bolt

30 Nm (3.0 m·kg, 22 ft·lb)

a

2

1

New

 

Recommended clutch fluid

Brake fluid DOT 4

1

2

a

CLUTCH

5-68

NOTE:

In order to ensure a correct reading of the clutch 
fluid level, make sure the top of the reservoir is 
horizontal.

4. Bleed:

• Clutch system

Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-15.

5. Check:

• Clutch fluid level

Below the minimum level mark “a” 

→

 Add the 

recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID 
LEVEL” on page 3-14.

6. Check:

• Clutch lever operation

Soft or spongy feeling 

→

 Bleed the clutch 

system.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-15.

ET1D71004

REMOVING THE CLUTCH RELEASE 
CYLINDER

1. Remove:

• Clutch pipe union bolt “1”
• Copper washers “2”
• Clutch pipe “3”

NOTE:

Put the end of the clutch pipe into a container 
and pump out the clutch fluid carefully.

EAS25330

CHECKING THE CLUTCH RELEASE 
CYLINDER

1. Install:

• Clutch release cylinder body

Cracks/damage 

→

 Replace the clutch re-

lease cylinder.

2. Check:

• Clutch release cylinder “1”
• Clutch release cylinder piston “2”

Rust/scratches/wear 

→

 Replace the clutch 

release cylinder and clutch release cylinder 
piston as a set.

EAS25340

ASSEMBLING THE CLUTCH RELEASE 
CYLINDER

WARNING

EW1D71006

• Before installation, all internal clutch com-

ponents must be cleaned and lubricated 
with clean or new clutch fluid.

• Never use solvents on internal clutch com-

ponents as they will cause the piston seal 
to swell and distort.

• Whenever a clutch release cylinder is dis-

assembled, replace the piston seal.

3

1

2

Recommended clutch component replace-

ment schedule

Piston seal

Every two years

Clutch hose

Every four years

Clutch fluid

Every two years and 
whenever the clutch 
is disassembled

 

Recommended clutch fluid

Brake fluid DOT 4

1

2

CLUTCH

5-69

EAS25350

INSTALLING THE CLUTCH RELEASE 
CYLINDER

1. Install:

• Copper washers 
• Clutch pipe “1”
• Clutch pipe union bolt “2”

WARNING

EW1D71003

Proper clutch pipe routing is essential to in-
sure safe vehicle operation. Refer to “CABLE 
ROUTING” on page 2-45.

CAUTION:

EC1D71005

When installing the clutch pipe onto the 
clutch release cylinder, make sure the pipe 
“a” touches the projection “b” on the clutch 
release cylinder.

2. Fill:

• Clutch master cylinder reservoir

(with the specified amount of the recom-
mended clutch fluid)

WARNING

EWA13370

• Use only the designated clutch fluid. Other 

clutch fluids may cause the rubber seals to 
deteriorate, causing leakage and poor 
clutch performance.

• Refill with the same type of clutch fluid that 

is already in the system. Mixing clutch flu-
ids may result in a harmful chemical reac-
tion, leading to poor clutch performance.

• When refilling, be careful that water does 

not enter the clutch fluid reservoir. Water 
will significantly lower the boiling point of 
the clutch fluid and could cause vapor lock.

CAUTION:

ECA13420

Clutch fluid may damage painted surfaces or 
plastic parts. Therefore, always clean up any 
spilt clutch fluid immediately.

NOTE:

In order to ensure a correct reading of the clutch 
fluid level, make sure that the top of the reservoir 
is horizontal.

3. Bleed:

• Clutch system

Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-15.

4. Check:

• Clutch fluid level

Below the minimum level mark “a” 

→

 Add the 

recommended clutch fluid to the proper level.
Refer to “CHECKING THE CLUTCH FLUID 
LEVEL” on page 3-14.

5. Check:

• Clutch lever operation

Soft or spongy feeling 

→

 Bleed the clutch 

system.
Refer to “BLEEDING THE HYDRAULIC 
CLUTCH SYSTEM” on page 3-15.

T

 

R

.

 

Clutch pipe union bolt

26 Nm (2.6 m·kg, 19 ft·lb)

 

Recommended clutch fluid

Brake fluid DOT 4

New

2

a

1

b

SHIFT SHAFT

5-70

EAS25410

SHIFT SHAFT

Removing the shift shaft and stopper lever

Order

Job/Parts to remove

Q’ty

Remarks

Clutch housing

Refer to “CLUTCH” on page 5-50.

1

Washer

3

2

Circlip

2

3

Shift shaft

1

4

Shift shaft spring

1

5

Stopper lever

1

6

Collar

1

7

Stopper lever spring

1

8

Shift shaft spring stopper

1

For installation, reverse the removal proce-
dure.

E

8

1

2

1

4

3

6

5

7

2

1

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

22 Nm (2.2 m 

•

 

kg, 16 ft

 

•

 

Ib)

LT

LT

LS

New

New

SHIFT SHAFT

5-71

EAS25420

CHECKING THE SHIFT SHAFT

1. Check:

• Shift shaft

Bends/damage/wear 

→

 Replace.

• Shift shaft spring

Damage/wear 

→

 Replace.

EAS25430

CHECKING THE STOPPER LEVER

1. Check:

• Stopper lever

Bends/damage 

→

 Replace.

Roller turns roughly 

→

 Replace the stopper 

lever.

• Stopper lever spring

Damage/wear 

→

 Replace.

EAS25450

INSTALLING THE SHIFT SHAFT

1. Install:

• Stopper lever “1”
• Collar
• Stopper lever bolt “2”
• Stopper lever spring “3”

NOTE:

• Hook the ends of the stopper lever spring onto 

the stopper lever and the crankcase boss “4”.

• Mesh the stopper lever with the shift drum seg-

ment assembly.

2. Install:

• Washers
• Circlips
• Shift shaft spring “1”
• Shift shaft “2”

NOTE:

Hook the end of the shift shaft spring onto the 
shift shaft spring stopper “3”.

T

 

R

.

 

Stopper lever bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
LOCTITE

®

2

1

3

4

2

1

3

GENERATOR AND STARTER CLUTCH

5-72

EAS24480

GENERATOR AND STARTER CLUTCH

Removing the stator coil

Order

Job/Parts to remove

Q’ty

Remarks

Engine oil

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

Muffler/Exhaust pipes

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

Lead cover

Refer to “BELT DRIVE” on page 4-80.

Clutch pipe

Refer to “CLUTCH” on page 5-50.

1

Stator coil coupler

1

Disconnect.

2

Oil delivery pipe 2

1

3

Generator cover

1

4

Generator cover gasket

1

5

Dowel pin

2

6

Stator coil lead holder

1

7

Stator coil

1

For installation, reverse the removal proce-
dure.

(5)

LT

LT

LT

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

3

T

 

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)

4

5

6

2

5

New

New

New

New

7

1

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

LS

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

E

GENERATOR AND STARTER CLUTCH

5-73

Removing the generator rotor

Order

Job/Parts to remove

Q’ty

Remarks

1

Torque limiter

1

2

Starter clutch idle gear shaft

1

3

Starter clutch idle gear

1

4

Generator rotor

1

5

Starter clutch

1

6

Woodruff key

1

7

Starter clutch gear

1

8

Bearing

1

9

Bearing housing

1

For installation, reverse the removal proce-
dure.

E

E

R

80 Nm (8.0 m 

•

 

kg, 58 ft

 

•

 

Ib)

T

 

E

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

4

6

2

3

1

5

(6)

E

7

T

 

R

24 Nm (2.4 m 

•

 

kg, 17 ft

 

•

 

Ib)

LT

LT

8

9

GENERATOR AND STARTER CLUTCH

5-74

EAS24490

REMOVING THE GENERATOR

1. Remove:

• Generator rotor bolt “1”
• Washer

NOTE:

While holding the generator rotor “2” with the 
sheave holder “3”, loosen the generator rotor 
bolt.

2. Remove:

• Generator rotor “1”

(with the rotor puller “2”)

• Woodruff key

EAS24560

REMOVING THE STARTER CLUTCH

1. Remove:

• Starter clutch bolts
• Starter clutch

NOTE:

While holding the generator rotor “1” with the 
sheave holder “2”, loosen the starter clutch 
bolts.

EAS24570

CHECKING THE STARTER CLUTCH

1. Check:

• Starter clutch rollers

Damage/wear 

→

 Replace.

2. Check:

• Starter clutch idle gear
• Starter clutch gear

Burrs/chips/roughness/wear 

→

 Replace the 

defective part(s).

3. Check:

• Starter clutch gear’s contacting surfaces

Damage/pitting/wear 

→

 Replace the starter 

clutch gear.

4. Check:

• Starter clutch operation

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▼

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▼

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a. Install the starter clutch gear “1” onto the 

starter clutch and hold the generator rotor “2”.

b. When turning the starter clutch gear clock-

wise “A”, the starter clutch and the starter 
clutch gear should engage, otherwise the 
starter clutch is faulty and must be replaced.

c. When turning the starter clutch gear counter-

clockwise “B”, it should turn freely, otherwise 
the starter clutch is faulty and must be re-
placed.

 

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

 

Rotor puller

90890-01080

Stator rotor puller

YM-01080-A

1

2

3

1

2

 

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

2

1

GENERATOR AND STARTER CLUTCH

5-75

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▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

ET1D71020

CHECKING THE TORQUE LIMITER

1. Check:

• Torque limiter

Damage/wear 

→

 Replace.

NOTE:

Do not disassemble the torque limiter.

EAS24600

INSTALLING THE STARTER CLUTCH

1. Install:

• Starter clutch

NOTE:

While holding the generator rotor “1” with the 
sheave holder “2”, tighten the starter clutch 
bolts.

EAS24510

INSTALLING THE GENERATOR

1. Install:

• Woodruff key

• Generator rotor “1”
• Washer
• Generator rotor bolt “2”

NOTE:

• Clean the tapered portion of the generator 

shaft and the generator rotor hub.

• When installing the rotor, make sure the woo-

druff key is properly seated in the key way of 
the generator shaft.

• Lubricate the generator rotor bolt threads and 

washer mating surfaces with engine oil.

2. Tighten:

• Generator rotor bolt “1”

NOTE:

While holding the generator rotor “2” with a 
sheave holder “3”, tighten the generator rotor 
bolt.

3. Apply:

• Sealant

(onto the stator coil lead grommet)

T

 

R

.

 

Starter clutch bolt

24 Nm (2.4 m·kg, 17 ft·lb)
LOCTITE

®

 

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

2

1

T

 

R

.

 

Generator rotor bolt

80 Nm (8.0 m·kg, 58 ft·lb)

 

Sheave holder

90890-01701

Primary clutch holder

YS-01880-A

1

2

1

2

3

GENERATOR AND STARTER CLUTCH

5-76

 

Yamaha bond No. 1215

90890-85505
(Three Bond No.1215

®

)

ELECTRIC STARTER

5-77

EAS24780

ELECTRIC STARTER

Removing the starter motor

Order

Job/Parts to remove

Q’ty

Remarks

1

Starter motor lead

1

Disconnect.

2

Starter motor

1

For installation, reverse the removal proce-
dure.

2

1

T

 

R

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

ELECTRIC STARTER

5-78

Disassembling the starter motor

Order

Job/Parts to remove

Q’ty

Remarks

1

Starter motor front cover

1

2

Bearing

1

3

Oil seal

1

4

Circlip

1

5

Starter motor rear cover

1

6

Brush

2

7

Brush holder (along with the brushes)

1

8

Brush seat (along with the brushes)

1

9

Bearing

1

10

Gasket

2

11

Armature assembly

1

12

Starter motor yoke

1

For assembly, reverse the disassembly pro-
cedure.

6

2

3

5

7

1

4

LS

New

New

New

New

New

New

10

9

10

8

12

11

LS

ELECTRIC STARTER

5-79

EAS24790

CHECKING THE STARTER MOTOR

1. Check:

• Commutator

Dirt 

→

 Clean with 600 grit sandpaper.

2. Measure:

• Commutator diameter “a”

Out of specification 

→

 Replace the starter 

motor.

3. Measure:

• Mica undercut “a”

Out of specification 

→

 Scrape the mica to the 

proper measurement with a hacksaw blade 
that has been grounded to fit the commutator.

NOTE:

The mica of the commutator must be undercut to 
ensure proper operation of the commutator.

4. Measure:

• Armature assembly resistances (commutator 

and insulation)
Out of specification 

→

 Replace the starter 

motor.

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▼

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a. Measure the armature assembly resistances 

with the pocket tester.

b. If any resistance is out of specification, re-

place the starter motor.

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5. Measure:

• Brush length “a”

Out of specification 

→

 Replace the brushes 

as a set.

6. Measure:

• Brush spring force

Out of specification 

→

 Replace the brush 

springs as a set.

 

Limit

27.5 mm (1.08 in)

 

Mica undercut (depth)

1.50 mm (0.06 in)

 

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

 

Armature coil

Commutator resistance “1”

0.0081–0.0099 

Ω

 at 20 °C (68 °F)

Insulation resistance “2”

Above 1 M

Ω

 at 20 °C (68 °F)

 

Limit

5.00 mm (0.20 in)

 

Brush spring force

7.36–11.04 N (26.49–39.74 oz) 
(750–1126 gf)