2013 Yamaha XV19 Series XV19SD/XV19CTSD/XV19CSD/XV19CD Service Manual (P/N LIT-11616-26-33)

Yamaha’s eight-chapter factory service manual, P/N LIT-11616-26-33, covers the 2013 XV19SD(C), XV19CTSD(C), XV19CSD(C), and XV19CD(C). This is the First Edition, July 2012, with maintenance, diagnosis, and repair procedures for the covered USA, California, and Canadian configurations.

Searchable Text, Bookmarks, and Color Wiring Diagrams

Search and diagram detail: Body text and wiring legends are searchable, and embedded PDF bookmarks link to chapters, major sections, and the two color wiring sheets. Small circuit labels, connector details, and wire codes require zooming for close inspection.

One printable PDF contains 500 pages total, including seven blank divider pages and a logo-only rear cover. The two full-page color wiring diagrams are also included in that total.

Engine, FI Diagnosis, and Chassis Repair

The following selected coverage highlights summarize the main workshop areas rather than reproduce the full contents. Other documented topics include instrument functions and headlight aiming.

• Engine repair: Step-by-step removal and internal service covering camshafts, rocker arms, push rods, hydraulic lifters, cylinder heads, valves, pistons, crankshaft, and connecting rods.

• Clutch and drivetrain: Wet-clutch service, clutch master- and release-cylinder rebuilding, generator and starter-clutch checks, transfer gear case work, and transmission assembly.

• Fuel injection: Fuel-pressure testing, throttle-body synchronization, throttle-position-sensor adjustment, ISC checks, and injector, rollover-valve, and pressure-regulator inspection.

• Chassis and brakes: Wheel balancing, caliper and master-cylinder repair, fork overhaul, steering-head service, rear-suspension and swingarm work, and drive-belt and pulley service.

• Electrical diagnosis: ECU fault-code tables, meter-based diagnostic mode, sensor and actuator tests, and ignition, starting, charging, lighting, signaling, and fuel-pump troubleshooting.

• Workshop references: Exploded assembly views, job charts, lubrication diagrams, routing plates, tightening sequences, torque tables, capacities, wear limits, clearances, and special-tool numbers.

Yamaha prepared this manual primarily for its dealers and their qualified mechanics; it assumes a basic understanding of mechanics and vehicle repair techniques.

Maintenance and Internal Engine Work

Periodic-service procedures cover ignition-timing checks, engine and transfer-gear oil changes, hydraulic clutch and brake bleeding, EXUP cable adjustment, drive-belt slack, steering-head inspection, rear-shock preload, and battery testing.

Internal engine coverage includes hydraulic-lifter bleeding, decompression-system checks, valve-guide replacement, valve-seat inspection and lapping, crankcase separation, and engine and transfer-gear oil-pump inspection. Connecting-rod bearing selection uses crankshaft and rod markings with a bearing color chart; transmission procedures address the shafts, shift forks, shift drum, and gear engagement.

The rear cylinder-head-cover notes explain the risk of scratching rocker arms or other engine parts with the cover bolts in the restricted frame clearance.

Fuel-System Testing and ECU Fault Isolation

The FI system schematic connects fuel delivery through the tank, pump, pressure regulator, twin injectors, and throttle bodies with ECU inputs, O2 feedback, and idle-speed control. Fuel-system sections distinguish the rollover-valve arrangements and California canister and purge-hose layouts.

Pressure-regulator testing uses a fuel-pressure gauge and vacuum/pressure pump. Throttle-body coverage includes removal, inspection, cleaning, synchronization, and sensor adjustment; Yamaha specifies that the throttle-body assemblies must not be disassembled.

ECU tables distinguish stored fault codes from diagnostic-mode codes and explain substitute operation, probable causes, and reinstatement checks. These references connect a displayed fault with the relevant wiring and component tests, helping the mechanic investigate the circuit before selecting replacement parts.

Fuel hoses can retain gasoline after the tank has been drained, and the hydraulic brake and clutch systems require the specified fluid and bleeding procedures. Follow the manual’s procedure-specific warnings before opening fuel or hydraulic circuits or charging the battery.

Chassis Families and Suspension Limits

The repair chapters distinguish XV19S(C)/XV19CTS(C) from XV19CS(C)/XV19C(C), with separate meter functions, exhaust checks, cable routing, fork and steering installation notes, and wiring diagrams.

Chassis data also separates steering geometry, wheel and rim packages, rear-brake arrangements, suspension specifications, and belt-reduction details. The forged-wheel XV19C(C)(1US) configuration is distinguished from the cast-wheel builds. Windshield, backrest, and sidebag-bracket procedures are included for the applicable configuration.

Rear-shock coverage addresses removal, inspection, preload adjustment, and suspension linkage; the gas-filled shock absorber itself must not be opened. Fork-disassembly notes warn that excessive separation force can damage seals and bushings, while bottoming the inner tube can damage the oil-flow stopper.

Diagrams, Routing, and Special Tools

Visual references include the FI system schematic, engine-oil lubrication chart, crankcase and transmission lubrication section views, model-specific cable-routing plates, starting-circuit cut-off diagram, and separate color wiring diagrams for the two model families.

Routing plates identify lead-pinching areas around the fuel-tank bracket and ECU. Fuel-hose illustrations also show the connector-cover positioning required for a secure connection.

The special-tool tables pair Yamaha 90890 numbers with applicable USA/Canada identifiers. Examples include the Vacuummate YU-44456, rear drive-belt tension gauge YM-03170, adjustable fork-seal driver YM-01442, valve-spring compressor YM-04019, fuel-pressure adapter YM-03176, and multimeter with tachometer YU-A1927.

Examples of Valve-Clearance and Sensor Test Specifications

For cold valve-train inspection, the specified clearance is 0.00–0.04 mm for both intake and exhaust valves. The procedure explains when manual rocker-arm adjustment is required despite the hydraulic lifters.

For crankshaft-position-sensor testing, the reference resistance is 248–372 Ω. The electrical section pairs this specification with the tester connections and a component-specific checking procedure.