Yamaha XV1700PCR Supplementary Service Manual
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Yamaha XV1700PCR Supplementary Service Manual

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XV1700PCR
XV1700PCRC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-16-36
5PX-28197-11

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Summary of Contents for Yamaha XV1700PCR

  • Page 1 XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL LIT-11616-16-36 5PX-28197-11...
  • Page 3 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)
  • Page 4 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.
  • Page 5 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 6 EAS00009 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 8 indicate the INFO subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting TRBL...

  • Page 7: Table Of Contents

    CONTENTS SPECIFICATIONS ................... 1 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 ..........11 INTRODUCTION ..................11 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ..........

  • Page 8: Specifications

    GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PX4 (USA) ---- 5PX5 (California) ---- 5PX6 (CDN) ---- ENGINE SPECIFICATIONS Item Standard Limit Electronic fuel injection Model (manufacturer) INP-732 (NIPPON INJECTOR) ---- Quantity ---- Crankshaft Width A 132.8 ~ 133.2 mm (5.228 ~ 5.244 in) ----...

  • Page 9: Electrical Specifications

    ---- 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 ---- 0.13 ~ 0.19 Ω/W–W Stator coil resistance/color ---- TIGHTENING TORQUES...

  • Page 10: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Brake hose È Fasten the rectifier/regulator Ê Fasten the rear brake light 2 Clutch cable lead, horn lead, and rear brake switch lead, horn lead, and 3 Rectifier/regulator light switch lead with a plastic stator coil assembly lead with 4 Rectifier/regulator lead locking tie to the frame.
  • Page 11 SPEC CABLE ROUTING 1 Tachometer couplers È Secure the wire harness in the holder at the 2 Right handlebar switch coupler and speedome- white tape on the harness. É Route each lead behind the headlight assembly ter couplers 3 Main switch coupler bracket bolts.
  • Page 12 SPEC CABLE ROUTING 1 Throttle cable 1 and throttle cable 2 È Pass throttle cable 1 and throttle cable 2 through 2 Clutch cable the cable guide, and then fasten them with a 3 Atmospheric pressure sensor plastic holder. 4 Spark plug cap (ignition coil 1-L spark plug lead) É...
  • Page 13 SPEC CABLE ROUTING Ë Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking tie. Ì Fasten the starter motor lead and side stand switch lead with a plastic locking tie to the frame. Í...
  • Page 14 SPEC CABLE ROUTING 1 Ignition coil 1 È To the rectifier/regulator, horn 1, and rear brake 2 Atmospheric pressure sensor lead light switch. 3 Ignition coil 2 É 30 ~ 50 degrees 4 Ignition coil 2 lead Ê 40 ~ 60 degrees 5 Rear brake light switch coupler 6 Rectifier/regulator lead and horn lead 7 Linear control valve lead...
  • Page 15 SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 H Ignition coil 1-R spark plug lead 2 Fuel hose 0 Throttle cables I Lean angle cut-off switch lead 3 Spark plug cap (ignition coil 1-R A Brake hose J Crankshaft position sensor lead B Spark plug cap (ignition coil 2-R K Sidestand switch lead...
  • Page 16 SPEC CABLE ROUTING È To the battery box. Í Fasten the main wire harness, intake air pres- É Fasten the main wire harness and fuel hose with sure sensor lead #2, ignition coil 1-R spark plug a plastic locking tie to the frame. lead, and intake air temperature sensor coupler Ê...
  • Page 17 SPEC CABLE ROUTING Ð To the injector sub lead. × To the speed sensor. Ñ To the engine temperature sensor. Ø Fasten the crankshaft position sensor lead, side- Ò 10 30 mm (0.4 1.2 in) stand switch lead, lean angle cut-off switch lead, Ó...

  • Page 18: Periodic Checks And Adjustments

    Evaporative Emission control • Check control system for damage. √ √ system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. – 11 –...

  • Page 19: General Maintenance And Lubrication Chart

    √ √ √ √ — ing and cable free play if necessary. • Lubricate the throttle grip housing and cable. Yamaha Chain and • Apply chain lube thor- Cable Lube or √ √ √ √ √ √ 9 * Control cables oughly.
  • Page 20 Every 2,500 mi (4,000 km) • Adjust if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.

  • Page 21: Chassis

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHASSIS EAS00156 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1.
  • Page 22 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting knob 1 in direction a or Rebound damping is Direction a increased (suspension...

  • Page 23: Chassis

    CHAS FRONT AND REAR BRAKES CHASSIS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • •...
  • Page 24 CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •...

  • Page 25: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 26 CHAS REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 27 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
  • Page 28 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Swingarm Dust cover Spacer Bearing For installation, reverse the removal...

  • Page 29: Engine

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENGINE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
  • Page 30 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 31: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH STATOR COIL ASSEMBLY 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 32 GENERATOR AND STARTER CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 34 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

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