Related Manuals for Yamaha XV17AS(C)
Summary of Contents for Yamaha XV17AS(C)
- Page 1 XV17AS(C) XV17ASS(C) XV17ATS(C) SUPPLEMENTARY SERVICE MANUAL LIT-11616-17-09 4WM-28197-E1...
- Page 2 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 ©2003 by Yamaha Motor Corporation, U.S.A. First Edition, May 2003 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.
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Page 3: Important Manual Information
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. -
Page 4: How To Use This Manual
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. 1 The manual is divided into chapters. - Page 5 SYMBOLS The following symbols are not relevant to every vehicle. SPEC Symbols 1 to 8 indicate the subject of each INFO chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system CARB 8 Troubleshooting TRBL...
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Page 6: Table Of Contents
CONTENTS SPECIFICATIONS ....................1 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 ..........27 INTRODUCTION ..................27 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................27 GENERAL MAINTENANCE AND LUBRICATION CHART .....27 SEATS AND SIDE COVERS ..............30... - Page 7 CARBURETOR ....................71 AIR INDUCTION SYSTEM ..............71 AIR INDUCTION SYSTEM DIAGRAMS ..........71 XV17AS(C)/XV17ASS(C)/XV17ATS(C) WIRING DIAGRAM...
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Page 8: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 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) ----... -
Page 9: Engine Specifications
SPEC ENGINE SPECIFICATIONS 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... - Page 10 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshaft exhaust cam dimensions Measurement A 38.236 ~ 38.336 mm (1.5054 ~ 1.5093 in) 38.136 mm (1.5014 in) Measurement B 32.013 ~ 32.113 mm (1.2604 ~ 1.2643 in) 31.913 mm (1.2564 in) Rocker arms, rocker arm shafts Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 18.036 mm (0.7101 in)
- Page 11 SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm (0.006 in) 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 (0.8679 in)
- Page 12 SPEC 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 ---- 35/32 × 70/32 (2.393) Secondary reduction ratio ---- Operation Left-foot operation ---- Gear ratios...
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Page 13: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Front wheel Wheel type Cast wheel ---- Spoke wheel (XV17A for CDN) ---- 16M/C × MT3.00 Size ---- Material Aluminum ---- Steel (XV17A for CDN) ---- Wheel travel 140 mm (5.51 in) ---- Wheel runout Maximum radial wheel runout... - Page 14 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front tire Tire type Tubeless ---- With tube (XV17A for CDN) ---- Size 130/90–16M/C 67H ---- Model (manufacturer) G703 N G703 F ---- (BRIDGESTONE) (BRIDGESTONE) (XV17A/XV17AS) (XV17A) G703 D404FL ---- (BRIDGESTONE) (DUNLOP) (XV17AT) (XV17A) G703 N ---- (BRIDGESTONE)
- Page 15 SPEC 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 ×...
- Page 16 SPEC 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) ---- –...
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Page 17: Electrical Specifications
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 10° BTDC at 900 r/min ---- Advancer type Throttle position sensor and electrical ---- 248 ~ 372 Ω/Gy—B Pickup coil resistance/color ---- Transistorized coil ignition unit model... -
Page 18: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size Nm m · kgf ft · lb Cylinder head Rocker arm base Bolt Rocker arm base Bolt Front cylinder camshaft end cover Bolt Carburetor joint clamp Screw Exhaust pipe Muffler... -
Page 19: Chassis Tightening Torques
SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks Nm m · kgf ft · lb Upper bracket and inner tube Handlebar holder (lower) and handlebar holder (upper) Throttle cable adjusting nut and locknut Engine mounting: Lower front mounting bolt 10.3 Lower rear mounting bolt Transfer gear case stay and frame... -
Page 20: Cable Routing
SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Right handlebar switch lead È To engine 2 Throttle cables É Route the rear brake light switch lead in front of 3 Brake hoses the rectifier/regulator bracket on the frame. 4 Clutch cable Ê... - Page 21 SPEC CABLE ROUTING 1 Rectifier/regulator lead B Horn lead 2 Rear brake light switch lead C Starter motor lead 3 Wire harness D Clutch cable 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...
- Page 22 SPEC CABLE ROUTING È Fasten the rectifier/regulator lead and rear brake Ì Fasten the air induction system vacuum hose light switch lead with the plastic holders. and spark plug lead #2 with the plastic holder. É Pass the left handlebar switch lead through the Í...
- Page 23 SPEC CABLE ROUTING Ð Fasten the horn lead and starter motor lead to Ö Fasten the fuel pump lead with the plastic the frame with the plastic locking tie. holder. Ñ Fasten the starter motor lead with the plastic holders. Ò...
- Page 24 SPEC CABLE ROUTING 1 Wire harness B Pickup coil lead 2 Spark plug cap #1 C Sidestand switch lead 3 Fuel sender lead D Horn lead 4 Negative battery lead E Decompression solenoid lead 5 Positive battery lead F Stator coil lead 6 Tail/brake light lead G Neutral switch lead 7 Starter relay...
- Page 25 SPEC CABLE ROUTING È To fuel sender Í 25 ~ 35 mm (0.98 ~ 1.38 in) É Fasten the wire harness and seat lock cable to Î Fasten the tail/brake light lead with the plastic the frame with the plastic band. holders.
- Page 26 SPEC CABLE ROUTING Ò Fasten the speed sensor lead, decompression solenoid lead, pickup coil lead, neutral switch lead, stator coil lead, sidestand switch lead, and horn lead with the plastic holder. Ó Fasten the starter motor lead, sidestand switch lead, and horn lead to the frame with the plastic locking ties.
- Page 27 SPEC CABLE ROUTING 1 Turn signal relay B Rear brake light switch lead 2 Relay unit C Sidestand switch coupler 3 Battery D Pickup coil lead 4 Oil tank breather hose E Horn leads 5 Fuel tank breather hose F Starter motor lead 6 Meter assembly lead G Sidestand switch lead 7 Throttle cables...
- Page 28 SPEC CABLE ROUTING È Fasten the fuel tank breather hose with the plas- Ð To decompression solenoid Ñ To speed sensor tic holder. É Fasten the throttle cables and fuel tank breather hose with the plastic holder. Ê Fasten the throttle cables with the plastic holder. Ë...
- Page 29 SPEC CABLE ROUTING 1 Left handlebar switch lead A Fuel sender lead 2 Throttle cables B Air induction system vacuum hose 3 Right handlebar switch lead C Solenoid valve lead (for California) 4 Fuel tank breather hose D Spark plug lead #4 5 Oil tank breather hose E Spark plug lead #2 6 Relay unit...
- Page 30 SPEC CABLE ROUTING È Fasten the left handlebar switch lead with the Î Route the starter motor lead between the battery plastic holders. box and plastic bracket. É Fasten the right handlebar switch lead with the Ï Install the sleeve of the negative battery lead plastic holders.
- Page 31 SPEC CABLE ROUTING Evaporative emission control system (for California) 1 Compensator A Charcoal canister 2 Compensator breather hose B Carburetor-to-charcoal-canister hose 3 3-way-joint-to-compensator hose C Solenoid-valve-to-3-way-joint hose 4 Main switch D Solenoid-valve-to-air-filter-case hose 5 Fuel tank breather hose E Solenoid valve 6 Rollover valve 7 Rollover-valve-to-3-way-joint hose 8 Surge-tank-to-3-way-joint hose...
- Page 32 SPEC CABLE ROUTING È Fasten the 3-way-joint-to-compensator hose Í Fasten the starter motor lead and horn lead with with the plastic holder. the plastic holder. É To solenoid valve Î To compensator Ê Fasten the compensator breather hose and 3- Ï...
- Page 33 SPEC CABLE ROUTING 1 Carburetor-to-surge-tank hose 2 3-way-joint-to-surge-tank hose 3 Surge tank 4 Surge-tank-to-3-way-joint hose 5 Carburetor-to-charcoal-canister hose 6 Solenoid valve 7 3-way-joint – 26 –...
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Page 34: Periodic Checks And Adjustments
• Check control system for damage. √ tem (For California • Replace if necessary. only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS... - Page 35 √ √ √ √ 24 * ing and cable sary. • Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the ser- vice. – 28 –...
- Page 36 GENERAL MAINTENANCE AND LUBRICATION CHART NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. NOTE: The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service •...
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Page 37: Seats And Side Covers
SEATS AND SIDE COVERS SEATS AND SIDE COVERS Order Job/Part Q’ty Remarks Removing the seats and side covers Remove the parts in the order listed. Rider seat Passenger seat Left side cover Right side cover For installation, reverse the removal pro- cedure. -
Page 38: Fuel Tank
FUEL TANK EAS00040 FUEL TANK 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “SEATS AND SIDE COVERS”. Meter assembly Meter assembly coupler Disconnect. -
Page 39: Chassis
CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Reflector (left and right) Brake caliper (left and right) Wheel axle pinch bolt... -
Page 40: Rear Wheel, Brake Disc And Rear Wheel Pulley
REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS PULLEY EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. - Page 41 REAR WHEEL, BRAKE DISC AND REAR WHEEL CHAS PULLEY Order Job/Part Q’ty Remarks Right adjusting plate Left adjusting plate Rear wheel axle Rear wheel Collar (left and right) Brake caliper bracket For installation, reverse the removal pro- cedure. – 34 –...
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Page 42: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. -
Page 43: Replacing The Front Brake Pads
CHAS FRONT AND REAR BRAKES EAS00580 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. - Page 44 CHAS FRONT AND REAR BRAKES 5. Install: • brake pad shims (onto the brake pads) • brake pads • brake pad spring NOTE: Always install new brake pads and a new brake pad spring as a set. M MMM M MMM M MMM M MMM M MMM...
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Page 45: Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Brake fluid Drain. Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose... - Page 46 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Left footrest assembly Cotter pin Brake master cylinder For installation, reverse the removal pro- cedure. – 39 –...
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Page 47: Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. - Page 48 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...
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Page 49: Disassembling The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 •... -
Page 50: Checking The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Every years and whenever the Brake fluid brake is disassem- bled 1. -
Page 51: Assembling And Installing The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •... - Page 52 CHAS FRONT AND REAR BRAKES 4. Fill: • brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
- Page 53 CHAS FRONT AND REAR BRAKES 7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. (Manual No.: 4WM-28197-E0) – 46 –...
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Page 54: Handlebar
CHAS HANDLEBAR EAS00664 HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Rear view mirror (left and right) Plastic clamp Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Right handlebar switch Throttle cable holder Throttle cable Disconnect. - Page 55 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Left handlebar switch Handlebar grip Clutch cable Disconnect. Clutch lever holder Cable guide Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal pro- cedure. – 48 –...
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Page 56: Rear Shock Absorber And Swingarm
CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. and swingarm Rear wheel Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. Adjusting bolt Locknut Mud guard... - Page 57 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Pivot shaft Rear shock absorber and swingarm assembly For installation, reverse the removal pro- cedure. – 50 –...
- Page 58 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. and swingarm Self-locking nut/washer/bolt 1/1/1 Bolt = 53 mm (2.19 in) Self-locking nut/washer/bolt 1/1/1 Bolt = 124 mm (4.88 in) Connecting arm O-ring Rear shock absorber...
- Page 59 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job/Part Q’ty Remarks Spacer/bearing Swingarm Dust cover Spacer Bearing For installation, reverse the removal pro- cedure. – 52 –...
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Page 60: Drive Belt And Drive Pulley
CHAS DRIVE BELT AND DRIVE PULLEY DRIVE BELT AND DRIVE PULLEY Order Job/Part Q’ty Remarks Removing the drive belt and drive Remove the parts in the order listed. pulley Rear wheel Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. Rear shock absorber and swingarm Refer to “REAR SHOCK ABSORBER assembly... -
Page 61: Engine
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENGINE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ® Quick Gasket ® Quick Gasket 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing cylinder head covers Remove the parts in the order listed. Engine left side cover Refer to “ROCKER ARMS, PUSH RODS Decompression solenoid cover... - Page 62 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the push rods and rocker Remove the parts in the order listed.
- Page 63 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the valve lifters Remove the parts in the order listed. Push rod cover O-ring Seal...
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Page 64: Installing The Rocker Arms And Push Rods
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin- ders. 1. Install: • rocker arms 1 • rocker arm shafts 2 (onto rocker arm base) NOTE: The thread hole a of the rocker arm shaft must face to the outside. -
Page 65: Installing The Cylinder Head Covers
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS c. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern. Rocker arm base bolt 1, 2 10 Nm (1.0 m · kg, 7.2 ft · lb) Rocker arm base bolt 3 24 Nm (2.4 m ·... -
Page 66: Clutch
CLUTCH EAS00274 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch cover Refer to “CLUTCH” in chapter 5. (Manual No.: 4WM-28197-E0) Generator rotor cover Refer to “GENERATOR AND STARTER CLUTCH” in chapter 5. (Manual No.: 4WM-28197-E0) Clutch spring plate retainer Clutch spring plate... - Page 67 CLUTCH Order Job/Part Q’ty Remarks Friction plate Clutch damper spring Clutch damper spring seat Clutch boss Thrust washer Clutch housing Circlip Oil pump drive gear Dowel pin Spacer Pickup coil rotor Primary drive gear Straight key For installation, reverse the removal pro- cedure.
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Page 68: Installing The Clutch Boss Nut
CLUTCH INSTALLING THE CLUTCH BOSS NUT 1. Install: • washer • clutch boss nut 1 105 Nm (10.5 m · kg, 75 ft · lb) NOTE: • Install the washer on the main axle with the “OUT” mark facing away from the motorcy- cle. -
Page 69: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS00343 GENERATOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Removing the generator rotor Remove the parts in the order listed. Generator cover Refer to “GENERATOR AND STARTER CLUTCH” in chapter 5. (Manual No.: 4WM-28197-E0) Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1... -
Page 70: Crankshaft And Connecting Rods
CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS EAS00398 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1. Measure: • crankshaft runout Out of specification → Replace the crank- shaft. Maximum crankshaft runout 0.04 mm (0.0016 in) 2. Check: • crankshaft journal surfaces •... - Page 71 CRANKSHAFT AND CONNECTING RODS b. Install the big end upper bearing into the connecting rod and the big end lower bear- ing into the connecting rod cap. NOTE: Align the projections a on the big end bear- ings with the notches b in the connecting rod and connecting rod cap.
- Page 72 CRANKSHAFT AND CONNECTING RODS WARNING When a bolt is tightened more than the specified angle, do not loosen them and then retighten them. Replace the bolt with a new one and per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.
- Page 73 CRANKSHAFT AND CONNECTING RODS 4. Select: • big end bearings (P NOTE: • The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes. • “P ”...
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Page 74: Installing The Connecting Rods
CRANKSHAFT AND CONNECTING RODS 6. Measure: • crankshaft journal bearing inside diameter a Out of specification → Replace the crank- case assembly. Crankshaft journal bearing inside diameter 50.01 ~ 50.03 mm (1.969 ~ 1.970 in) NOTE: Measure the inside diameter of each crank- shaft journal bearing at two places. - Page 75 CRANKSHAFT AND CONNECTING RODS 2. Lubricate: • crankshaft pins • big end bearings • connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 3. Install: • big end bearings • connecting rods • connecting rod caps (onto the crankshaft pins) NOTE: •...
- Page 76 CRANKSHAFT AND CONNECTING RODS M MMM M MMM M MMM M MMM M MMM a. Tighten the connecting rod bolts to the specified torque. Connecting rod bolts 15 mm (1.5 m · kg, 11 ft · lb) b. Tighten the connecting rod bolts further to reach the specified angle 90°...
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Page 77: Transmission
TRANSMISSION TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle assem- Remove the parts in the order listed. Main axle assembly Refer to “TRANSMISSION” in chapter 5. (Manual No.: 4WM-28197-E0) Circlip Washer 5th pinion gear 2nd/3rd pinion gear Circlip Washer 4th pinion gear Spacer Main axle/1st pinion gear... -
Page 78: Air Induction System
CARB AIR INDUCTION SYSTEM CARBURETOR AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve È To the carburetor joint 2 Air cut-off valve É To the air cut-off valve 3 Front cylinder head 4 Rear cylinder head 5 Air cleaner 6 Carburetor joint È... - Page 79 CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Removing the air induction system Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK” Fuel pump Refer to “CARBURETOR” in chapter 6. (Manual No.: 4WM-28197-E0) Reed valve case to rear cylinder head hose 1 Reed valve case to rear cylinder head pipe 1...
- Page 80 CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Reed valve case to front cylinder head pipe Rectifier/regulator coupler Disconnect. Rectifier/regulator Air filter bracket Air filter Air filter cover Air filter hose Air cut-off valve to air filter hose Plastic locking tie Vacuum hose Bracket Air cut-off valve holder...
- Page 81 CARB AIR INDUCTION SYSTEM Order Job/Part Q’ty Remarks Air cut-off valve to reed valve cover hose Reed valve cover Reed valve case Reed valve base Reed valve stopper Reed valve For installation, reverse the removal pro- cedure. – 74 –...
- Page 82 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
- Page 83 XV17AS(C)/XV17ASS(C)/XV17ATS(C) WIRING DIAGRAM 1 Generator 2 Rectifier/regulator 3 Main switch G/R B/W 4 Battery W L2 5 Main fuse ( BLACK ) Gy L Lg Sb 6 Starter relay Y L/R L/B B/L Sb/W 7 Starter motor Sb/W R/B L L/B L/R L/G L/Y Sb 8 Backup fuse...