Yamaha XV17PCV 2005 Supplementary Service Manual
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Yamaha XV17PCV 2005 Supplementary Service Manual

Yamaha XV17PCV 2005 Supplementary Service Manual

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XV17PCV(C)
XV17PCMV(C)
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-19-46
5PX-28197-12

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Summary of Contents for Yamaha XV17PCV 2005

  • Page 1 XV17PCV(C) XV17PCMV(C) SUPPLEMENTARY SERVICE MANUAL LIT-11616-19-46 5PX-28197-12...
  • Page 2 XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10) XV1700PCR/XV1700PCRC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-16-36 (5PX-28197-11) XV17PCV(C)/XV17PCMV(C) SUPPLEMENTARY SERVICE MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. First edition, June 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.
  • Page 3 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 4 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 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 6: Table Of Contents

    CONTENTS SPECIFICATIONS ....................1 GENERAL SPECIFICATIONS ..............1 ENGINE SPECIFICATIONS ................ 1 CHASSIS SPECIFICATIONS............... 4 ELECTRICAL SPECIFICATIONS ..............4 TIGHTENING TORQUES................5 ENGINE TIGHTENING TORQUES ............5 CHASSIS TIGHTENING TORQUES ............. 6 LUBRICATION POINTS AND LUBRICANT TYPES ........6 ENGINE ....................6 CABLE ROUTING ..................

  • Page 7: Specifications

    GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 2D84 (XV17PCMV for USA) ---- 2D85 (XV17PCMV(C) for California) ---- 5PXG (XV17PCV for USA) ---- 5PXH (XV17PCV(C) for California) ---- ENGINE SPECIFICATIONS Item Standard Limit Engine oil Lubrication system Dry sump ----...
  • Page 8 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston pin bore (in the piston) Diameter 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm (0.8679 in) Offset 1.0 mm (0.0394 in) ---- Piston pins Outside diameter 21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in) 21.971 mm (0.8650 in) Piston pin-to-piston pin bore clear- 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) 0.074 mm...
  • Page 9 SPEC ENGINE SPECIFICATIONS Item Standard Limit Crankshaft Width A 105.8 ~ 106.2 mm (4.165 ~ 4.181 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...

  • Page 10: Chassis Specifications

    CHASSIS SPECIFICATIONS/ SPEC ELECTRICAL SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Single-disc brake ---- Operation Right-foot operation ---- Brake pedal free play 0 mm (0 in) ---- Brake pedal position 86 mm (3.4 in) ---- (from the top of the rider footrest to the top of the brake pedal) Recommended fluid DOT 4...

  • Page 11: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Front cylinder camshaft end cover Bolt Oil filter bracket Bolt A.I.S. bracket Bolt Crankshaft position sensor Bolt Stator coil assembly Screw Generator rotor Bolt Use a lock Clutch boss...

  • Page 12: Chassis Tightening Torques

    TIGHTENING TORQUES/ SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Throttle stop screw bracket and seat bracket Throttle stop screw bracket and frame Left side cover 1 and left side cover 2 Lean angle sensor bracket and frame Sidestand bracket and frame Front brake caliper...

  • Page 13: Cable Routing

    SPEC CABLE ROUTING È Fasten the left handlebar switch lead with the CABLE ROUTING plastic holders. 1 Clutch cable É Fasten the right handlebar switch lead with the 2 Left handlebar switch lead plastic holders. 3 Right handlebar switch lead Ê...
  • Page 14 SPEC CABLE ROUTING È Be sure to position the ECU leads and sensor 1 Negative battery lead 2 Tail/brake light lead leads toward the left side of the vehicle, and 3 Seat lock cable then fasten the wire harness protector with a 4 Fuel pump lead plastic locking tie.
  • Page 15 SPEC CABLE ROUTING Ê Place the couplers (crankshaft position sensor Î Fasten the decompression solenoid lead, speed coupler, sidestand switch coupler, decompres- sensor lead, cylinder identification sensor lead, sion solenoid couplers, tail/brake light coupler, sidestand switch lead, crankshaft position sen- cylinder identification sensor coupler and speed sor lead, neutral switch lead, and fuel pump lead sensor coupler) in the tray.
  • Page 16 SPEC CABLE ROUTING Ï Position the gray mark on the starter motor lead at the center of the bolt. Fit the starter motor lead and sidestand switch lead into the groove in the frame, and then fasten them with a plastic lock- ing tie.
  • Page 17 SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 G Neutral switch lead 2 Fuel hose 0 Throttle cables H Speed sensor lead 3 Spark plug cap (ignition coil A Brake hose I Ignition coil 1-R spark plug lead B Main wire harness J Oil temperature sensor lead 1-R spark plug lead)
  • Page 18 SPEC CABLE ROUTING È To the battery box. Ë Route the throttle position sensor lead, engine É Fasten the oil temperature sensor lead with the temperature sensor lead, injector lead, and igni- lead holder. tion coil 1-R spark plug lead in the order listed Ê...
  • Page 19 SPEC CABLE ROUTING Ì Fasten the main wire harness and ignition coil 1- Í Fasten the throttle position sensor lead, engine R spark plug lead to the frame between the air temperature sensor lead, and injector lead with filter case joint and the fuel hose with a plastic a plastic locking tie to the fuel delivery pipe.
  • Page 20 SPEC CABLE ROUTING Î Fasten the main wire harness and ignition coil 1- Ï Fasten the main wire harness, intake air pres- R spark plug lead to the frame between the sure sensor 2 lead, ignition coil 1-R spark plug intake air pressure sensor 1 and the fuel hose lead, and intake air temperature sensor coupler with a plastic locking tie, making sure to install...
  • Page 21 SPEC CABLE ROUTING Ò Fasten the rear brake light switch lead and igni- Ó Fasten the main wire harness and intake vac- tion coil 2-R spark plug lead to the pipe section uum hose with a plastic locking tie. Ô To the engine temperature sensor. of the linear control valve bracket with a plastic Õ...
  • Page 22 SPEC CABLE ROUTING Ù Position the gray mark on the stator coil lead at Þ Route the oil temperature sensor lead under the the center of the bolt, and then fasten it with a rear engine bracket (right). ß Position the buckle of the plastic locking tie so plastic locking tie.
  • Page 23 SPEC CABLE ROUTING Fasten the crankshaft position sensor lead, Fasten the corrugated tube with the plastic sidestand switch lead, lean angle sensor lead, locking tie. Face the end of the plastic locking starter motor lead, and horn 2 lead with a plas- tie outward, and then cut off the excess end of tic locking tie.

  • Page 24: Periodic Checks And Adjustments

    • Check control system for damage. √ √ • Replace if necessary. tem (For California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. – 18 –...

  • Page 25: General Maintenance And Lubrication Chart

    GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months...
  • Page 26 • Adjust the headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

  • Page 27: Seat And Side Covers

    SEAT AND SIDE COVERS EAS00038 SEAT AND SIDE COVERS 16 Nm (1.6 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft •...

  • Page 28: Fuel Tank

    FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 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. Seat Refer to “SEAT AND SIDE COVERS”. Air induction system cover Air duct Fuel hose joint 1...

  • Page 29: Installing The Fuel Hose Joint 2

    FUEL TANK INSTALLING THE FUEL HOSE JOINT 2 1. Install: • fuel hose joint 2 1 • hose joint cover 2 NOTE: Install the hose joint cover completely onto fuel hose joint 2. – 23 –...

  • Page 30: Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 35 Nm (3.5 m kg, 25 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 31 CHAS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 35 Nm (3.5 m kg, 25 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •...

  • Page 32: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 35 Nm (3.5 m kg, 25 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.

  • Page 33: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 35 Nm (3.5 m kg, 25 ft • • 32 Nm (3.2 m kg, 23 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 34 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...

  • Page 35: 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 36 CHAS FRONT AND REAR BRAKES 3. Install: • brake pads • brake pad spring • brake caliper bolts 35 Nm (3.5 m · kg, 25 ft · lb) • brake hose holders 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: The arrow a on the brake pad spring must point in the direction of rotation.
  • Page 37 CHAS FRONT AND REAR BRAKES 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. (Manual No.: 5PX-28197-10) 7.

  • Page 38: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft •...

  • Page 39: 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” in chapter 4.
  • Page 40 CHAS DRIVE BELT AND DRIVE PULLEY Order Job/Part Q’ty Remarks Drive pulley For installation, reverse the removal procedure. – 34 –...

  • Page 41: Installing The Drive Belt And Drive Pulley

    CHAS DRIVE BELT AND DRIVE PULLEY INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1. Install: • drive pulley 1 • conical spring washer 2 • drive pulley nut 3 NOTE: • Lubricate the drive pulley nut threads and conical spring washer mating surface with engine oil.

  • Page 42: Engine

    ENGINE ENGINE ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks...
  • Page 43 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Engine oil/oil filter cartridge Drain.
  • Page 44 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Oil filter bracket Rectifier/regulator coupler...
  • Page 45 ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •...
  • Page 46 ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •...

  • Page 47: Transfer Gear Case

    TRANSFER GEAR CASE TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 48 TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • L L T T 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 49: Installing The Transfer Gear Case

    TRANSFER GEAR CASE INSTALLING THE TRANSFER GEAR CASE 1. Install: • middle driven shaft 1 • middle drive gear 2 • primary chain 3 (into the transfer gear case) • drive pulley nut 4 NOTE: • Install the middle driven shaft, middle drive gear and primary chain at the same time.
  • Page 50 TRANSFER GEAR CASE 5. Tighten: • middle driven gear nut 1 100 Nm (10.0 m · kg, 72 ft · lb) NOTE: Stake the middle driven gear nut 1 at a cutout a in the drive axle. 6. Remove: • drive pulley nut 7.

  • Page 51: Crankcase

    CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Removing the baffle plate and Remove the parts in the order listed. bearings Crankshaft Refer to “CRANKSHAFT AND CON- NECTING RODS” in chapter 5. (Manual No.: 5PX-28197-10) Transmission Refer to “TRANSMISSION”. Baffle plate Bearing retainer Bearing retainer Oil seal Bearing...

  • Page 52: Installing The Bearing Retainer

    CRANKCASE INSTALLING THE BEARING RETAINER 1. Install: • Bearing retainer 1 NOTE: • Install the bearing retainer 1 with its “OUT” mark a facing outward. ® • Apply locking agent (LOCTITE ) to the threads of the bearing retainer bolt. –...

  • Page 53: Transmission

    TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE” in chapter 5. (Manual No.: 5PX-28197-10) Shift fork guide bar Shift drum assembly Shift fork “L”...
  • Page 54 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. assembly Circlip Washer 5th pinion gear Spacer Washer 2nd/3rd pinion gear Circlip Washer 4th pinion gear Spacer Main axle/1st pinion gear For assembly, reverse the disassembly procedure.
  • Page 55 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly 5th wheel gear Circlip Washer 2nd wheel gear Spacer Circlip Washer 1st wheel gear Spacer Washer 4th wheel gear Circlip – 49 –...
  • Page 56 TRANSMISSION Order Job/Part Q’ty Remarks Washer 3rd wheel gear Spacer Drive axle For assembly, reverse the disassembly procedure. – 50 –...
  • Page 57 XV17PCV(C)/XV17PCMV(C) 2006 WIRING DIAGRAM Br/B Lg BR L LG LY Sb BY LW/1 Br/B (BLACK) (BLACK) WIREHARNESS TAIL SUB-WIREHARNESS WIREHARNESS INJECTION SUB-WIREHARNESS L/W1 (BLUE) (BLUE) Y W/Y Br/W (BLACK) Br/L Y/R R/L Y/R L/W (GRAY) (BLACK) L W/Y (BLACK) Br/L Br/L Br/L Br/L...

  • Page 58: Xv17Pcv(C)/Xv17Pcmv(C) 2006 Wiring Diagram

    XV17PCV(C)/XV17PCMV(C) 2006 WIRING DIAGRAM 1 Generator o Front turn signal/position light COLOR CODE 2 Rectifier/regulator (right) B.... Black 3 Main switch p Rear turn signal light (right) B3..Black 3 4 Battery q Rear turn signal light (left) Br ..Brown 5 Backup fuse (odometer and r Headlight Ch ..
  • Page 59 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 60 XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL LIT-11616-16-36 5PX-28197-11...
  • Page 61 Supplementary Service Manual together with the following manual. XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10) XV1700PCR/XV1700PCRC SUPPLEMENTARY SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. First Edition, July 2002 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.
  • Page 62 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 63 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 64 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 65 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 66: 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 67: 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 ---- Stator coil resistance/color 0.13 ~ 0.19 Ω/W–W ---- TIGHTENING TORQUES...

  • Page 68: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING È Fasten the rectifier/regulator Ê Fasten the rear brake light 1 Brake hose 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 69 SPEC CABLE ROUTING È Secure the wire harness in the holder at the 1 Tachometer couplers 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 70 SPEC CABLE ROUTING È Pass throttle cable 1 and throttle cable 2 through 1 Throttle cable 1 and throttle cable 2 2 Clutch cable the cable guide, and then fasten them with a 3 Atmospheric pressure sensor plastic holder. É Fasten the engine stop switch lead, horn lead, 4 Spark plug cap (ignition coil 1-L spark plug lead) 5 Horn lead and oil temperature sensor lead with a plastic...
  • Page 71 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 72 SPEC CABLE ROUTING È To the rectifier/regulator, horn 1, and rear brake 1 Ignition coil 1 2 Atmospheric pressure sensor lead light switch. É 30 ~ 50 degrees 3 Ignition coil 2 Ê 40 ~ 60 degrees 4 Ignition coil 2 lead 5 Rear brake light switch coupler 6 Rectifier/regulator lead and horn lead 7 Linear control valve lead...
  • Page 73 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 74 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 75 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 76: 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 77: 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 √ √ √ √ √...
  • Page 78 √ • 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 79: 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 80 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 81: 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 82 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 83: 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 84 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 85 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 86 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 87: 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 88 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 89: 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 90 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 91 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

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