Yamaha XV17AS, XV17ASS, XV17ATS Supplementary Service Manual

XV17AS(C)

XV17ASS(C)

XV17ATS(C)

SUPPLEMENTARY

SERVICE MANUAL

LIT-11616-17-09 4WM-28197-E1

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the XV17AS(C)/XV17ASS(C)/XV17ATS(C). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual.

XV16AL/XV16ALC/XV16ATL/XV16ATLC SERVICE MANUAL:

LIT-11616-12-56 (4WM-28197-E0)

XV17AS(C)/XV17ASS(C)/XV17ATS(C)

SUPPLEMENTARY SERVICE MANUAL

First Edition, May 2003

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-11616-17-09

EAS00003

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 with 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.

This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully.

NOTE:

Designs and specifications are subject to change without notice.

EAS00004

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:

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.

NOTE:

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

EAS00007

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

CARB

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

Carburetor

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 ......................................................................2

CHASSIS SPECIFICATIONS ....................................................................6

ELECTRICAL SPECIFICATIONS ...........................................................10

TIGHTENING TORQUES .......................................................................11

ENGINE TIGHTENING TORQUES ....................................................11

CHASSIS TIGHTENING TORQUES ..................................................12

CABLE ROUTING ...................................................................................13

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION .....................................................................................27

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM ..................................................................................................27

GENERAL MAINTENANCE AND LUBRICATION CHART .....................27

SEATS AND SIDE COVERS ..................................................................30

FUEL TANK .............................................................................................31

CHASSIS

FRONT WHEEL AND BRAKE DISCS ....................................................32

REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY .................33

FRONT AND REAR BRAKES .................................................................35

HANDLEBAR ..........................................................................................47

REAR SHOCK ABSORBER AND SWINGARM ......................................49

DRIVE BELT AND DRIVE PULLEY ........................................................53

........................................................................................................32

FRONT BRAKE PADS ........................................................................35

REPLACING THE FRONT BRAKE PADS ..........................................36

REAR BRAKE MASTER CYLINDER ..................................................38

FRONT BRAKE CALIPERS ................................................................40

DISASSEMBLING THE FRONT BRAKE CALIPERS .........................42

CHECKING THE FRONT BRAKE CALIPERS ....................................43

ASSEMBLING AND INSTALLING THE FRONT BRAKE

CALIPERS ..........................................................................................44

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

..................................................27

ENGINE

..........................................................................................................54

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS .........................54

INSTALLING THE ROCKER ARMS AND PUSH RODS ....................57

INSTALLING THE CYLINDER HEAD COVERS .................................58

CLUTCH ..................................................................................................59

INSTALLING THE CLUTCH BOSS NUT ............................................61

GENERATOR AND STARTER CLUTCH ................................................62

CRANKSHAFT AND CONNECTING RODS ...........................................63

CHECKING THE CRANKSHAFT AND CONNECTING RODS ..........63

INSTALLING THE CONNECTING RODS ..........................................67

TRANSMISSION .....................................................................................70

CARBURETOR ...............................................................................................71

AIR INDUCTION SYSTEM ......................................................................71

AIR INDUCTION SYSTEM DIAGRAMS .............................................71

XV17AS(C)/XV17ASS(C)/XV17ATS(C) WIRING DIAGRAM

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code

Dimensions

Overall length 2,500 mm (98.4 in) ---Overall width 980 mm (38.6 in) ---Overall height 1,140 mm (44.9 in) (XV17A/XV17AS)

Seat height 710 mm (28.0 in) ---Wheelbase 1,688 mm (66.5 in) ---Minimum ground clearance 145 mm (5.71 in) ---Minimum turning radius 3,200 mm (126 in) ----

Weight

Wet (with oil and a full fuel tank) 334 kg (736 lb) (XV17A/XV17AS)

Dry (without oil and fuel) 312 kg (688 lb) (XV17A/XV17AS)

Maximum load (total of cargo, rider, passenger, and accessories)

5VN1 (XV17A for USA) 5VN2 (XV17A for California) 5VN6 (XV17A for CDN) 5VR1 (XV17AS for USA) 5VR2 (XV17AS for California) 5VR3 (XV17AS for CDN) 5VP1 (XV17AT for USA) 5VP2 (XV17AT for California) 5VP3 (XV17AT for CDN) 5VP4 (XV17AT for Hawaii)

1,500 mm (59.1 in) (XV17AT)

349 kg (769 lb) (XV17AT)

327 kg (721 lb) (XV17AT) 194 kg (428 lb) (XV17A/XV17AS)

179 kg (395 lb) (XV17AT)

----

– 1 –

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Engine

Engine type Air-cooled, 4-stroke, OHV ---Displacement 1,670 cm Cylinder arrangement V-type 2-cylinder ---Bore × stroke 97 × 113 mm (3.82 × 4.45 in) ---Compression ratio 8.36 : 1 ---Engine idling speed 850 ~ 950 r/min ---Vacuum pressure at engine idling

speed Standard compression pressure (at sea level)

Camshafts

Drive system Gear drive ---Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) ---Camshaft cover hole inside diameter 28.000 ~ 28.021 mm (1.1024 ~ 1.1032 in) ---Camshaft journal diameter

(crankcase side) Camshaft journal diameter

(camshaft cover side) Camshaft to crankcase clearance 0.050 ~ 0.084 mm (0.0020 ~ 0.0033 in) ---Camshaft to camshaft cover clear-

ance Camshaft intake cam dimensions

43.3 kPa (325 mm Hg, 12.8 in Hg) ----

1,200 kPa (12.0 kgf/cm

24.937 ~ 24.950 mm (0.9818 ~ 0.9823 in) ----

27.967 ~ 27.980 mm (1.1011 ~ 1.1016 in) ----

0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) ----

, 171 psi) at 200 r/min

----

Measurement A (front cylinder) 38.242 ~ 38.342 mm (1.5056 ~ 1.5095 in) 38.142 mm

(1.5017 in)

(rear cylinder) 38.241 ~ 38.341 mm (1.5055 ~ 1.5095 in) 38.141 mm

(1.5016 in)

Measurement B 31.977 ~ 32.077 mm (1.2589 ~ 1.2629 in) 31.877 mm

(1.2550 in)

– 2 –

ENGINE SPECIFICATIONS

Item Standard Limit

Camshaft exhaust cam dimensions

Measurement A 38.236 ~ 38.336 mm (1.5054 ~ 1.5093 in) 38.136 mm

Measurement B 32.013 ~ 32.113 mm (1.2604 ~ 1.2643 in) 31.913 mm

Rocker arms, rocker arm shafts

Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 18.036 mm

Rocker arm shaft outside diameter 17.976 ~ 17.991 mm (0.7077 ~ 0.7083 in) ---Rocker arm to rocker arm shaft clear-

ance

Valve lifters

Valve lifter outside diameter 22.962 ~ 22.974 mm (0.9040 ~ 0.9045 in) ---Valve lifter case inside diameter 23.000 ~ 23.021 mm (0.9055 ~ 0.9063 in) ---Valve lifter-to-valve lifter case clear-

ance

Valve push rods

Valve push rod length 1 288.25 ~ 288.75 mm (11.348 ~ 11.368 in) ---Valve push rod length 2 290.25 ~ 290.75 mm (11.427 ~ 11.447 in) ---Valve push rod runout 0.3 mm (0.012 in) ----

Cylinders

Bore 97.000 ~ 97.010 mm (3.8189 ~ 3.8193 in) ---Maximum taper ---- 0.05 mm

Maximum out of round ---- 0.05 mm

0.009 ~ 0.042 mm (0.0004 ~ 0.0017 in) 0.08 mm

0.026 ~ 0.059 mm (0.0010 ~ 0.0023 in) ----

SPEC

(1.5014 in)

(1.2564 in)

(0.7101 in)

(0.003 in)

(0.0016 in)

– 3 –

ENGINE SPECIFICATIONS

Item Standard Limit

Pistons

Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm

Diameter D 96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in) ----

Height H 5 mm (0.20 in) ---Piston pin bore (in the piston)

Diameter 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm

Offset 1.0 mm (0.04 in) ----

Piston pins

Outside diameter 21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in) 21.971 mm

Piston pin-to-piston pin bore clearance

Piston rings

Top ring

0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) 0.074 mm

SPEC

(0.006 in)

(0.8679 in)

(0.8650 in)

(0.0029 in)

Ring type Barrel ---Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) ---End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.65 mm

(0.026 in)

Ring side clearance 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.12 mm

(0.0047 in)

2nd ring

Ring type Taper ---Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) ---End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.8 mm

(0.031 in)

Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm

(0.0047 in)

Oil ring

Dimensions (B × T) 2.5 × 3.4 mm (0.098 × 0.134 in) ---End gap (installed) 0.2 ~ 0.7 mm (0.008 ~ 0.028 in) ----

– 4 –

ENGINE SPECIFICATIONS

Item Standard Limit

Transmission

Transmission type Constant mesh, 5-speed ---Primary reduction system Spur gear ---Primary reduction ratio 72/47 (1.532) ---Secondary reduction system Belt drive ---Secondary reduction ratio 35/32 × 70/32 (2.393) ---Operation Left-foot operation ---Gear ratios

1st gear 38/16 (2.375) ---2nd gear 30/19 (1.579) ---3rd gear 29/25 (1.160) ---4th gear 29/32 (0.906) ---5th gear 21/28 (0.750) ----

Maximum main axle runout ---- 0.08 mm

Maximum drive axle runout ---- 0.08 mm

Fuel pump

Pump type Electrical ---Model (manufacturer) UC-Z10C (MITSUBISHI) ---Output pressure 15 ~ 20 kPa

(0.15 ~ 0.20 kgf/cm

Carburetor

Model (manufacturer) × quantity BSR40 (MIKUNI) × 1 ---Throttle cable free play (at the flange

of the throttle grip) ID mark 5VN1 00

Main jet #182.5 ---Main air jet #60 ---Jet needle 6HDC26-1 ---Needle jet X-2M ---Pilot air jet 1 #100 ---Pilot air jet 2 2.0 ---Pilot outlet 1.1 ---Pilot jet #35 ---Bypass 1 0.9 ---Bypass 2 1.0 ---Bypass 3 0.9 ---Valve seat size 2.0 ---Starter jet 1 0.65 ---Starter jet 2 0.7 ---Butterfly valve size #110 ---Fuel level (above the float chamber

mating surface)

4 ~ 6 mm (0.16 ~ 0.24 in) ----

5VN2 10 (for California)

4.0 ~ 5.0 mm (0.16 ~ 0.20 in) ----

, 2.13 ~ 2.84 psi)

SPEC

(0.003 in)

----

– 5 –

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Front wheel

Wheel type Cast wheel

Spoke wheel (XV17A for CDN)

Rim

Size 16M/C × MT3.00 ---- Material Aluminum

Steel (XV17A for CDN) Wheel travel 140 mm (5.51 in) ---Wheel runout

Maximum radial wheel runout ----

----

Maximum lateral wheel runout ----

----

Rear wheel

Wheel type Cast wheel

Spoke wheel (XV17A for CDN) Rim

Size 16M/C × MT3.50 ---- Material Aluminum

Steel (XV17A for CDN) Wheel travel 110 mm (4.33 in) ---Wheel runout

Maximum radial wheel runout ----

----

Maximum lateral wheel runout ----

----

1 mm (0.04 in) 2 mm (0.08 in) (XV17A for CDN)

0.5 mm (0.02 in) 2 mm (0.08 in) (XV17A for CDN)

1 mm (0.04 in) 2 mm (0.08 in) (XV17A for CDN)

0.5 mm (0.02 in) 2 mm (0.08 in) (XV17A for CDN)

----

– 6 –

CHASSIS SPECIFICATIONS

SPEC

Item Standard Limit

Front tire

Tire type Tubeless

With tube (XV17A for CDN) Size 130/90–16M/C 67H ---Model (manufacturer) USA CDN

G703 N

(BRIDGESTONE)

(XV17A/XV17AS)

G703

(BRIDGESTONE)

(XV17AT)

G703 F (BRIDGESTONE) (XV17A) D404FL (DUNLOP) (XV17A) G703 N (BRIDGESTONE) (XV17AS) G703 (BRIDGESTONE) (XV17AT)

Tire pressure (cold)

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

, 36 psi) ----

, 36 psi) ---* Load is the total weight of the cargo, rider, passenger and accessories. Minimum tire tread depth ---- 1.0 mm

(0.04 in)

Rear tire

Tire type Tubeless

With tube (XV17A for CDN) Size 150/80B16M/C 71H ---Model (manufacturer) USA CDN

G702 N

(BRIDGESTONE)

(XV17A/XV17AS)

G702

(BRIDGESTONE)

(XV17AT)

G702 (BRIDGESTONE) (XV17A/XV17AT) D404 (DUNLOP) (XV17A) G702 N (BRIDGESTONE) (XV17AS)

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm 90 kg (198 lb) ~ Maximum load* 280 kPa (2.8 kg/cm High-speed riding 280 kPa (2.8 kg/cm

, 36 psi) ----

, 41 psi) ----

* Load is the total weight of the cargo, rider, passenger and accessories.

Minimum tire tread depth ---- 1.0 mm

(0.04 in)

----

– 7 –

CHASSIS SPECIFICATIONS

Item Standard Limit

Front brakes

Brake type Dual-disc brake ---Operation Right-hand operation ---Brake lever free play (lever end) 2 ~ 5 mm (0.08 ~ 0.20 in) ---Recommended fluid DOT 4 ---Brake discs

Diameter × thickness 298 × 5 mm (11.7 × 0.20 in) ---Minimum thickness ---- 4.5 mm

Maximum deflection ----

----

Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm

SPEC

(0.18 in)

0.1 mm (0.004 in)

0.15 mm (0.006 in) (XV17A for CDN)

(0.02 in)

Master cylinder inside diameter 14.0 mm (0.55 in) ---Caliper cylinder inside diameter 27.00 mm (1.06 in) and

30.20 mm (1.19 in)

Rear brake

Brake type Single-disc brake ---Operation Right-foot operation ---Brake pedal position (from the top of

the brake pedal to the bottom of the rider footrest board) Recommended fluid DOT 4 ---Brake discs

Diameter × thickness 320 × 7 mm (12.6 × 0.28 in) ---Minimum thickness ---- 6.5 mm

Maximum deflection ---- 0.15 mm

Brake pad lining thickness 7.0 mm (0.28 in) 0.5 mm

100 mm (3.9 in) ----

(0.26 in)

(0.006 in)

(0.02 in)

----

Master cylinder inside diameter 12.7 mm (0.5 in) ---Caliper cylinder inside diameter 33.96 mm (1.34 in) and

----

30.23 mm (1.19 in)

– 8 –

CHASSIS SPECIFICATIONS

Item Standard Limit

Drive belt

Model (manufacturer) UBD-0681 ---Drive belt slack (on a sidestand) 6 ~ 8 mm (0.24 ~ 0.31 in) ---Drive belt slack (on a suitable stand) 7 ~ 9 mm (0.28 ~ 0.35 in) ----

SPEC

– 9 –

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage Ignition system

Ignition system type Transistorized coil ignition (digital) ---Ignition timing 10° BTDC at 900 r/min ---Advancer type Throttle position sensor and electrical ---Pickup coil resistance/color 248 ~ 372 Ω/Gy—B ---- Transistorized coil ignition unit model

(manufacturer)

Ignition coils

Model (manufacturer) JO447 (DENSO) ---Minimum ignition spark gap 6 mm (0.24 in) ---Primary coil resistance 1.32 ~ 1.78 Ω ---- Secondary coil resistance 12 ~ 18 kΩ ----

Bulbs (voltage/wattage × quantity)

Headlight 12 V 60 W/55 W × 1 ---Tail/brake light LED ---Front turn signal/position light 12 V 23 W/8 W × 2 ---Rear turn signal light 12 V 21 W × 2 ---Licence plate light 12 V 5 W × 1 ---Meter light 14 V 0.56 W × 4 ---Neutral indicator light 14 V 1.12 W × 1 ---Turn signal indicator light 14 V 1.12 W × 1 ---High beam indicator light 14 V 1.12 W × 1 ---Fuel level indicator light LED ---Engine trouble indicator light LED ----

Turn signal relay

Relay type Semi-transistor ---Model (manufacturer) FB257H (DENSO) ---Self-cancelling device built-in Yes ---Turn signal blinking frequency 75 ~ 95 cycles/min. ---Wattage 23 W × 2 + 3.4 W ----

Fuel sender

Model (manufacturer) 5VN (NIPPON SEIKI) ---Resistance 13 ~ 140 Ω at 20 °C (68 °F) ----

Sidestand relay

Model (manufacturer) G8R-30Y-X (OMRON) ---Coil resistance 162 ~ 198 Ω ----

Fuel pump relay model (manufacturer)

Thermo switch model (manufacturer)

12 V ----

J4T139 (MITSUBISHI) ----

G8R-30Y-X (OMRON) ----

5FU (NIPPON THERMOSTAT) ----

– 10 –

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Item Fastener

Thread

size

Tightening torque

Q’ty

Nm m · kgf ft · lb

Remarks

Cylinder head Nut M12 8 60 6.0 43 Rocker arm base Bolt M8 4 24 2.4 17 Rocker arm base Bolt M6 8 10 1.0 7.2 Front cylinder camshaft end cover Bolt M5 2 7 0.7 5.1 Carburetor joint clamp Screw M4 1 4 0.4 2.9 Exhaust pipe Nut M8 4 20 2.0 14 Muffler Bolt M10 2 35 3.5 25 Muffler clamp Bolt M8 2 20 2.0 14 Generator rotor Bolt M12 1 80 8.0 58 Pickup coil rotor Bolt M12 1 100 10.0 72 Clutch boss Nut M20 1 105 10.5 75 Stake Pull lever Bolt M6 1 12 1.2 8.7

Middle drive gear Nut M22 1 100 10.0 72

Use a lock

washer. Drive pulley case Bolt M10 3 50 5.0 36 Drive pulley case Bolt M8 4 30 3.0 22

Drive pulley Nut M22 1 100 10.0 72

Use a lock

washer. Shift arm Bolt M6 2 14 1.4 10 Neutral switch Screw M6 2 4 0.4 2.9

– 11 –

CHASSIS TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Item Thread size

Upper bracket and inner tube M6 18 1.8 13 Handlebar holder (lower) and handlebar holder

(upper) Throttle cable adjusting nut and locknut M6 4 0.4 2.9 Engine mounting:

Lower front mounting bolt M12 103 10.3 74 Lower rear mounting bolt M12 88 8.8 64

Transfer gear case stay and frame M10 72 7.2 52 Muffler stay and frame M10 53 5.3 38 Fuel sender and fuel tank M6 8 0.8 5.8 Rear fender side mold and rear fender stay M8 28 2.8 20 Sidestand bolt M10 89 8.9 64 Sidestand nut M10 32 3.2 23 Rear brake fluid reservoir M6 9 0.9 6.5 Grip end M16 23 2.3 17

M8 28 2.8 20

Tightening torque

Nm m · kgf ft · lb

Remarks

– 12 –

EB206000

CABLE ROUTING

Right handlebar switch lead

Throttle cables

Brake hoses

Clutch cable

Left handlebar switch lead

Air induction system vacuum hose

Rectifier/regulator

Rear brake light switch lead

CABLE ROUTING

To engine

Route the rear brake light switch lead in front of

the rectifier/regulator bracket on the frame. To rear brake light switch

Fasten the rear brake light switch lead with the

plastic holder. Fasten the rear brake light switch lead and recti-

fier/regulator lead with the plastic locking tie.

SPEC

– 13 –

CABLE ROUTING

SPEC

1 Rectifier/regulator lead 2 Rear brake light switch lead 3 Wire harness 4 Seat lock cable 5 Throttle position sensor coupler 6 Carburetor heater coupler 7 Air induction system vacuum hose 8 Fuel pump lead 9 Spark plug cap #1 0 Spark plug cap #3 A Horn

B Horn lead C Starter motor lead D Clutch cable

– 14 –

CABLE ROUTING

SPEC

È Fasten the rectifier/regulator lead and rear brake

light switch lead with the plastic holders.

É Pass the left handlebar switch lead through the

left brake hose guide and the right handlebar switch lead through the right brake hose guide under the upper bracket.

Ê Fasten the wire harness with the plastic holder. Ë Fasten the wire harness and seat lock cable to

the frame with the plastic band.

Ì Fasten the air induction system vacuum hose

and spark plug lead #2 with the plastic holder.

Í Fasten the wire harness, seat lock cable, spark

plug lead #1, and spark plug lead #2 to the engine bracket with the plastic band.

Î Fasten the spark plug lead #1 and spark plug

lead #2 with the plastic holder.

Ï Fasten the wire harness, seat lock cable, and

spark plug lead #1 with the plastic band.

– 15 –

CABLE ROUTING

SPEC

Ð Fasten the horn lead and starter motor lead to

the frame with the plastic locking tie.

Ñ Fasten the starter motor lead with the plastic

holders.

Ò Fasten the clutch cable with the plastic holders. Ó To air cut-off valve Ô To engine Õ Fasten the throttle position sensor lead, carbure-

tor heater lead, and fuel pump lead to the fuel pump bracket with the plastic locking tie.

Ö Fasten the fuel pump lead with the plastic

holder.

– 16 –

CABLE ROUTING

SPEC

1 Wire harness 2 Spark plug cap #1 3 Fuel sender lead 4 Negative battery lead 5 Positive battery lead 6 Tail/brake light lead 7 Starter relay 8 Thermo switch 9 Starter motor lead 0 Fuel tank breather hose A Horn

B Pickup coil lead C Sidestand switch lead D Horn lead E Decompression solenoid lead F Stator coil lead G Neutral switch lead H Speed sensor lead I Clutch cable

H G F E

DC B A0

ÓÓÒ

Î Ï

A B

– 17 –

CABLE ROUTING

SPEC

È To fuel sender É Fasten the wire harness and seat lock cable to

the frame with the plastic band.

Ê Fasten the wire harness, fuel sender lead and

seat lock cable with the plastic locking tie.

Ë Fasten the wire harness and all leads that

branch off from the wire harness with the plastic band.

Ì Fasten the wire harness and negative battery

lead with the plastic holder.

Í 25 ~ 35 mm (0.98 ~ 1.38 in) Î Fasten the tail/brake light lead with the plastic

holders.

Ï Pass the positive battery lead through the hole in

the battery box.

Ð Fasten the sidestand switch lead, horn lead,

starter motor lead, and pickup coil lead with the plastic holder.

Ñ Fasten the pickup coil lead with the metal holder.

H G F E

DC B A0

ÓÓÒ

Î Ï

A B

– 18 –

+ 58 hidden pages

Yamaha XV17AS, XV17ASS, XV17ATS Supplementary Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual