YAMAHA XV1700PCR, XV1700PCRC SERVICE MANUALS

XV1700PCR

XV1700PCRC

SUPPLEMENTARY

SERVICE MANUAL

LIT-11616-16-36 5PX-28197-11

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the XV1700PCR/XV1700PCRC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10)

XV1700PCR/XV1700PCRC

SUPPLEMENTARY SERVICE MANUAL

First Edition, July 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-16-36

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NOTICE

This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

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IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

CAUTION:

NOTE:

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

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HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”.

Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s) appears.

Sub-section titles appear in smaller print than the section title.

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step.

Symbols indicate parts to be lubricated or replaced. Refer to “SYMBOLS”.

A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

Jobs requiring more information (such as special tools and technical data) are described sequentially.

GEN

SPEC

INFO

CHK

CHAS

ADJ

ENG

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SYMBOLS

The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter.

General information

Specifications

Periodic checks and adjustments

Chassis

Engine

Fuel injection system

Electrical system

Troubleshooting

–+

TRBL

ELEC

SHTG

GHI

Symbols 9 to F indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points.

JKL

New

Engine oil

Gear oil

Molybdenum-disulfide oil

Wheel-bearing grease

Lithium-soap-based grease

Molybdenum-disulfide grease

Symbols M to N in the exploded diagrams indicate the following.

Apply locking agent (LOCTITE

Replace the part

)

CONTENTS

SPECIFICATIONS

GENERAL SPECIFICATIONS ................................................................. 1

ENGINE SPECIFICATIONS .................................................................... 1

CHASSIS SPECIFICATIONS ................................................................... 1

ELECTRICAL SPECIFICATIONS ............................................................ 2

TIGHTENING TORQUES ......................................................................... 2

CHASSIS TIGHTENING TORQUES .................................................... 2

CABLE ROUTING .................................................................................... 3

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION .................................................................................... 11

PERIODIC MAINTENANCE CHART FOR

THE EMISSION CONTROL SYSTEM ................................................ 11

GENERAL MAINTENANCE AND LUBRICATION CHART .................... 12

CHASSIS ................................................................................................ 14

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ............. 14

CHASSIS

FRONT AND REAR BRAKES ................................................................ 16

REAR SHOCK ABSORBER AND SWINGARM ..................................... 18

....................................................................................................... 16

REAR BRAKE MASTER CYLINDER ................................................. 16

........................................................................................... 1

................................................. 11

ENGINE

.......................................................................................................... 22

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ....................... 22

GENERATOR AND STARTER CLUTCH ............................................... 24

STATOR COIL ASSEMBLY ............................................................... 24

GENERAL SPECIFICATIONS/

ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code

ENGINE SPECIFICATIONS

Item Standard Limit

Electronic fuel injection

Model (manufacturer) INP-732 (NIPPON INJECTOR) ---Quantity 2 ----

Crankshaft

5PX4 (USA) 5PX5 (California) 5PX6 (CDN)

----

Width A 132.8 ~ 133.2 mm (5.228 ~ 5.244 in) ---Max. runout C ---- 0.04 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) 0.09 mm

(0.0035 in) Crankshaft journal-to-crankshaft-

journal bearing clearance

Fuel pump

Pump type Electrical ---Model (manufacturer) 5PX (MITSUBISHI) ---Max. consumption amperage 5 A ---Output pressure 392 ~ 588 kPa

0.032 ~ 0.062 mm (0.0012 ~ 0.0024 in) 0.1 mm (0.0039 in)

(3.92 ~ 5.88 kg/cm

, 55.7 ~ 83.6 psi)

CHASSIS SPECIFICATIONS

Item Standard Limit

Front tire

Tire type Tubeless ---Size 120/70 ZR 18 M/C (59 W)

120/70 ZR 18 (59 W)

Model (manufacturer) D220F ST G (DUNLOP)/

BT020F G (BRIDGESTONE)

----

– 1 –

CHASSIS SPECIFICATIONS/

ELECTRICAL SPECIFICATIONS/TIGHTENING TORQUES

Item Standard Limit

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm 90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kgf/cm High-speed riding 250 kPa (2.5 kgf/cm

* Load is the total weight of the cargo,

rider, passenger and accessories.

Min. tire tread depth ---- 1.0 mm

Rear tire

Tire type Tubeless ---Size 200/50 ZR 17 M/C (75 W)

200/50 ZR 17 (75 W)

Model (manufacturer) D220 ST (DUNLOP)/

BT020R (BRIDGESTONE)

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm 90 kg (198 lb) ~ Maximum load* 290 kPa (2.9 kgf/cm High-speed riding 250 kPa (2.5 kgf/cm

* Load is the total weight of the cargo,

rider, passenger and accessories.

Min. tire tread depth ---- 1.0 mm

, 36 psi) ----

, 42 psi) ----

, 36 psi) ----

SPEC

(0.04 in)

----

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Ignition coils

Model (manufacturer) J0447 (DENSO) ---Minimum ignition spark gap 6 mm (0.24 in) ---Primary coil resistance 1.32 ~ 1.78 Ω ---Secondary coil resistance 12 ~ 18 kΩ ----

Charging system

System type AC magneto ---Model (manufacturer) F5PX (YAMAHA) ---Nominal output 14 V/31 A at 5,000 r/min ---Stator coil resistance/color 0.13 ~ 0.19 Ω/W–W ----

TIGHTENING TORQUES

CHASSIS TIGHTENING TORQUES

Item Thread size

Rider footrest bracket and frame M10 48 4.8 35

Rear fender and turn signal light bracket (upper) M6 7 0.7 5.1 Rear fender and turn signal light bracket (lower) M6 9 0.9 6.5 Canister and rider footrest bracket (For California

M6 9 0.9 6.5

only)

Tightening torque

Nm m·kg ft·lb

Remarks

– 2 –

EB206000

CABLE ROUTING

Brake hose

Clutch cable

Rectifier/regulator

Rectifier/regulator lead

Rear brake light switch lead

Horn lead

Stator coil assembly lead

CABLE ROUTING

Fasten the rectifier/regulator

lead, horn lead, and rear brake light switch lead with a plastic locking tie to the frame. Fasten the stator coil assem-

bly lead and rectifier/regulator lead with a plastic clamp.

SPEC

Fasten the rear brake light

switch lead, horn lead, and stator coil assembly lead with a plastic locking tie to the frame. Fasten the stator coil assem-

bly lead, horn lead, and rear brake light switch lead with a plastic locking tie to the frame.

– 3 –

CABLE ROUTING

SPEC

1 Tachometer couplers 2 Right handlebar switch coupler and speedome-

ter couplers

3 Main switch coupler 4 Left handlebar switch couplers 5 Left and right turn signal/position light connec-

tors

È Secure the wire harness in the holder at the

white tape on the harness.

É Route each lead behind the headlight assembly

bracket bolts.

– 4 –

+ 23 hidden pages