Yamaha XV1700PCRC Road Star Warrior Manuals

Manuals and User Guides for Yamaha XV1700PCRC Road Star Warrior. We have 3 Yamaha XV1700PCRC Road Star Warrior manuals available for free PDF download: Service Manual, Owner's Manual, Supplementary Service Manual

Yamaha XV1700PCRC Road Star Warrior Service Manual (606 pages)

Motorcycle

Brand: Yamaha | Category: Motorcycle | Size: 26.52 MB

Important Manual Information
3
How to Use this Manual
4
Symbols
5
Table of Contents
6
Chassis Specifications
7
Engine Specifications
7
General Specifications
7
Electrical Specifications
8
- Chassis Tightening Torques
  8
Cable Routing
9
Periodic Checks and Adjustments

17
Chassis

22
- Rear Shock Absorber and Swingarm
  24
Engine

28
Chapter 1 General Information

50
Motorcycle Identification

50
- Vehicle Identification Number
  50
- Model Label
  50
Features

51
- Outline
  51
- FI System
  52
  - Fuel Control Block
    53
  - Components
    54
    
    ECU (Electronic Control Unit)
    54
    
    Fuel Pump
    57
    
    Pressure Regulator
    58
    
    Fuel Injector
    59
    
    Crankshaft Position Sensor
    60
    
    Cylinder Identification
    61
    
    Cylinder Identification Sensor
    61
    
    Throttle Position Sensor
    62
    
    Intake Air Pressure Sensor and Atmospheric Pressure Sensor
    63
    
    Engine Temperature Sensor
    64
    
    Intake Temperature Sensor
    64
    
    Lean Angle Cut-Off Switch
    65
    
    Detection of Intake Air Volume
    66
    
    Determining the Basic Injection Duration
    66
  - Fuel Injection System
    66
    
    Operation and Control
    66
    
    Fuel Injection Duration During Linear Control Valve Operation
    67
    
    Determining the Final Injection Duration
    68
    
    List of Fuel Injection Compensations
    69
    
    Reactive Injection Duration
    69
    
    Fuel Control During Normal Driving
    70
    
    Fuel Injection Compensation Control
    72
    
    After-Start Enrichment
    73
    
    Warm-Up Enrichment
    74
    
    Acceleration Enrichment
    75
    
    Deceleration Control
    76
    
    Over-Revolution Control
    76
    
    Basic Operation
    77
  - First Idle Control System
    77
  - Components
    78
  - Linear Control Valve
    78
  - Instrument Panel
    79
  - ECU Transmission Data and Meter Display
    79
  - DIAG Mode Inspection and Adjustment (Multi-Function Meter)
    80
Important Information

81
- Preparation for Removal and Disassembly
  81
- Replacement Parts
  81
- Gaskets, Oil Seals and O-Rings
  81
- Lock Washers/Plates and Cotter Pins
  82
- Bearings and Oil Seals
  82
- Circlips
  82
Checking the Connections

83
Special Tools

84
Chapter 2 Specifications

89
General Specifications

89
Engine Specifications

90
Chassis Specifications

101
Electrical Specifications

105
Conversion Table

108
General Tightening Torque Specifications

108
- Engine Tightening Torques
  109
- Chassis Tightening Torques
  112
Lubrication Points and Lubricant Types

115
- Engine
  115
- Chassis
  116
Engine Oil Lubrication Chart

117
Engine Oil Flow Diagrams

118
Transfer Gear Oil Flow Diagrams

122
Cable Routing

124
Chapter 3 Periodic Checks and Adjustments

139
Introduction

139
Periodic Maintenance Chart for the Emission Control System

139
General Maintenance and Lubrication Chart

140
Seat and Side Covers

142
Headlight and Meter Assemblies

143
Battery

144
Fuel Tank

145
Air Filter Case

146
Silencer Air Filter Case

147
- Adjusting the Valve Clearance
  149
Engine

149
- Synchronizing the Throttle Bodies
  153
- Adjusting the Engine Idling Speed
  155
- Adjusting the Throttle Cable Free Play
  156
  - Throttle Body Side
    156
  - Handlebar Side
    157
  - Checking the Spark Plugs
    158
  - Checking the Ignition Timing
    160
  - Engine Idling Speed
    160
  - Measuring the Compression Pressure
    161
  - Checking the Engine Oil Level
    164
  - Changing the Engine Oil
    165
  - Measuring the Engine Oil Pressure
    169
  - Checking the Transfer Gear Oil Level
    170
  - Changing the Transfer Gear Oil
    171
  - Adjusting the Clutch Cable Free Play
    173
  - Cleaning the Air Filter Elements
    174
  - Checking the Fuel Hoses
    175
  - Checking the Throttle Body Joints
    175
  - Checking the Cylinder Head Breather Hose and Oil Tank Breather Hose
    176
  - Checking the Exhaust System
    177
  - Adjusting the Front Brake
    178
Chassis

178
- Adjusting the Rear Brake
  179
- Checking the Brake Fluid Level
  180
- Checking the Front Brake Pads
  181
- Checking the Rear Brake Pads
  181
- Adjusting the Rear Brake Light Switch
  182
- Checking the Front and Rear Brake Hoses
  182
- Bleeding the Hydraulic Brake System
  183
- Adjusting the Drive Belt Slack
  185
- Adjusting the Shift Pedal
  185
- Checking and Adjusting the Steering Head
  188
- Checking the Front Fork
  190
- Adjusting the Front Fork Legs
  191
- Adjusting the Rear Shock Absorber Assembly
  192
- Checking the Tires
  193
  - Front Tire
    195
  - Rear Tire
    195
  - Checking and Lubricating the Cables
    196
  - Checking the Wheels
    196
  - Lubricating the Levers and Pedals
    197
  - Lubricating the Rear Suspension
    197
  - Lubricating the Sidestand
    197
Electrical System

198
- Checking and Charging the Battery
  198
  - Charging Method Using a Variable-Current (Voltage) Charger
    201
  - Charging Method Using a Constant Voltage Charger
    202
  - Checking the Fuses
    203
  - Replacing the Headlight Bulb
    206
  - Adjusting the Headlight Beam
    207
  - Instrument Functions
    208
  - Odometer and Tripmeter
    208
  - Adjusting the Clock
    209
  - Adjusting the Meter Light
    209
Chapter 4 Chassis

210
- Disassembling the Front Wheel
  212
- Checking the Front Wheel
  213
- Removing the Front Wheel
  213
- Checking the Brake Discs
  215
- Installing the Front Wheel
  216
- Adjusting the Front Wheel Static Balance
  218
Front Wheel and Brake Discs

210
Rear Wheel, Brake Disc, and Rear Wheel Pulley

220
- Removing the Rear Fender
  220
- Removing the Rear Wheel
  221
- Removing the Brake Disc and Rear Wheel Pulley
  223
- Disassembling the Rear Wheel
  225
- Checking the Rear Wheel
  226
- Assembling the Rear Wheel
  227
- Checking and Replacing the Rear Wheel Pulley
  227
- Checking the Rear Wheel Drive Hub
  227
- Installing the Rear Wheel
  228
- Adjusting the Rear Wheel Static Balance
  231
- Front Brake Pads
  232
- Removing the Front Brake Pads
  232
Front and Rear Brakes

232
- Removing the Rear Brake Pads
  233
- Front Brake Master Cylinder
  239
Front Fork

264
- Removing the Front Fork Legs
  264
- Disassembling the Front Fork Legs
  265
- Disassembling the Front Fork Legs
  267
- Removing the Front Fork Legs
  267
- Checking the Front Fork Legs
  269
- Assembling the Front Fork Legs
  271
- Installing the Front Fork Legs
  276
Handlebar

278
- Removing the Handlebar
  278
- Checking the Handlebar
  280
- Installing the Handlebar
  280
Steering Head

284
- Checking the Steering Head
  286
- Removing the Lower Bracket
  286
- Installing the Steering Head
  287
Rear Shock Absorber and Swingarm

289
Chapter 5 Engine

301
- Installing the Engine
  309
- Installing the Muffler and Exhaust Pipes
  310
Rocker Arms, Push Rods and Valve Lifters

311
Camshafts

325
- Removing the Camshafts
  327
- Checking the Camshafts
  328
- Checking the Decompression System
  330
- Checking the Oil Delivery Pipe
  330
- Installing the Camshafts
  331
Cylinder Heads

334
- Removing the Cylinder Heads
  336
- Checking the Cylinder Heads
  336
- Installing the Cylinder Head
  337
- Checking the Oil Delivery Pipe
  337
Valves and Valve Springs

339
- Removing the Valves
  340
- Checking the Valves and Valve Guides
  341
- Checking the Valve Seats
  343
- Checking the Valve Springs
  346
- Installing the Valves
  347
Cylinders and Pistons

349
- Removing the Cylinders and Pistons
  350
- Checking the Cylinders and Pistons
  351
- Checking the Piston Rings
  352
- Checking the Piston Pins
  353
- Installing the Pistons and Cylinders
  354
- Clutch Cover
  356
- Clutch
  357
- Removing the Clutch
  361
  - Checking the Clutch Plates
    362
  - Checking the Friction Plates
    362
  - Removing the Primary Drive Gear
    362
  - Checking the Clutch Plate Spring
    363
  - Checking the Pressure Plate
    364
  - Checking the Primary Drive
    364
  - Checking the Pull Lever Shaft and Pull Rod
    364
  - Installing the Crankshaft Position Sensor and Pull Lever Shaft
    364
  - Installing the Primary Drive Gear
    365
  - Installing the Clutch
    366
Shift Shaft and Stopper Lever

370
Generator and Starter Clutch

373
- Stator Coil Assembly
  373
- Checking the Starter Clutch
  376
- Removing the Generator
  376
- Installing the Generator
  377
Transfer Gear Case

379
- Fuel Pump
  382
- Install the Fuel Pump
  383
- Removing the Fuel Pump
  383
- Sub Fuel Tank
  384
- Removing the Middle Driven Shaft
  388
- Checking the Oil Pump
  389
- Checking the Oil Strainer
  389
- Assembling the Oil Pump
  390
- Checking the Oil Pipe
  390
- Installing the Transfer Gear Case
  391
Crankcase

393
- Disassembling the Crankcase
  396
- Checking the Crankcase
  397
  - Checking the Bearings and Oil Seals
    398
  - Checking the Engine Oil Pump Drive
    398
  - Checking the Oil Delivery Pipe
    398
  - Assembling the Crankcase
    399
Engine Oil Pump

402
- Checking the Oil Pump
  405
- Checking the Relief Valve
  405
- Assembling the Oil Pump
  406
- Checking the Oil Strainer
  406
- Installing the Oil Pump
  407
- Installing the Oil Strainer
  408
Crankshaft and Connecting Rods

409
- Checking the Crankshaft and Connecting Rods
  410
- Removing the Connecting Rods
  410
- Removing the Crankshaft
  410
  - Installing the Connecting Rods
    416
  - Installing the Crankshaft
    418
Transmission

419
- Checking the Shift Forks
  422
- Checking the Shift Drum Assembly
  423
- Checking the Transmission
  423
- Installing the Shift Forks and Shift Drum Assembly
  424
- Installing the Transmission
  424
Chapter 6 Fuel Injection System

426
- Wiring Diagram
  427
- Ecu's Self-Diagnostic Function
  429
Air Induction System

468
- Air Cut-Off Valve
  468
- Air Cut-Off Valve Assembly and Air Induction System Hoses
  469
- Reed Valves
  470
- Checking the Pressure Regulator
  471
- Checking the Air Induction System
  471
Chapter 7 Electrical System

472
Electrical Components

472
Arrangement of the Electrical Components and Couplers

474
Checking Switch Continuity

479
Checking the Switches

480
Checking the Bulbs and Bulb Sockets

482
- Types of Bulbs
  482
- Checking the Condition of the Bulbs
  482
- Checking the Condition of the Bulb Sockets
  484
- Checking the Leds
  485
Starter Motor

498
- Checking the Starter Motor
  501
- Assembling the Starter Motor
  503
Charging System

505
- Circuit Diagram
  505
  - Charging System Troubleshooting
    506
  - The Battery Is Not Being Charged
    506
  - Lighting System Circuit Diagram
    508
  - Lighting System Troubleshooting
    509
  - Checking the Lighting System
    510
    
    Signaling System Circuit Diagram
    514
    
    Signaling System Troubleshooting
    516
    
    The Horn Fails to Sound
    516
  - Checking the Signaling System
    517
    
    Fuel Injection System Circuit Diagram
    524
    
    Fuel Injection System Troubleshooting
    526
    
    If the Fuel Injection System Fails to Operate
    526
  - Checking and Adjusting the Throttle Position Sensor
    534
  - Checking the Fuel Pump
    534
Chapter 8 Troubleshooting

538
- Engine
  538
- Fuel System
  538
Starting Failures

538
Incorrect Engine Idling Speed

539
- Electrical Systems
  539
- Fuel System
  539
Poor Medium-And-High-Speed Performance

540
Faulty Gear Shifting

540
Faulty Clutch

540
- Engine
  540
- Fuel System
  540
- Shifting Is Difficult
  540
- Shift Pedal Does Not Move
  540
- Jumps out of Gear
  540
- Clutch Slips
  540
- Clutch Drags
  540
  - Overheating
    541
  - Poor Braking Performance
    541
  - Faulty Front Fork Legs
    541
  - Unstable Handling
    542
  - Faulty Lighting or Signaling System
    543
  - Headlight Does Not Come on
    543
  - Headlight Bulb Burnt out
    543
  - Tail/Brake Light Does Not Come on
    543
  - XV1700P/XV1700PC Wiring Diagram
    544
Specifications

553
- General Specifications
  553
- Engine Specifications
  553
- Chassis Specifications
  556
- Electrical Specifications
  556
- Tightening Torques
  557
- Engine Tightening Torques
  557
- Chassis Tightening Torques
  558
- Lubrication Points and Lubricant Types
  558
- Engine
  558
- Cable Routing
  559
Periodic Checks and Adjustments

570
- Introduction
  570
- Periodic Maintenance Chart for the Emission Control
  570
- System
  570
- General Maintenance and Lubrication Chart
  571
- Seat and Side Covers
  573
- Fuel Tank
  574
- Installing the Fuel Hose Joint 2
  575
Chassis

576
- Front Wheel and Brake Discs
  576
- Front and Rear Brakes
  578
- Front Brake Pads
  578
- Front Brake Calipers
  579
- Assembling and Installing the Front Brake
  579
- Calipers
  580
- Front Fork
  584
- Drive Belt and Drive Pulley
  585
- Installing the Drive Belt and Drive Pulley
  587
Engine

588
- Transfer Gear Case
  593
- Installing the Transfer Gear Case
  595
- Crankcase
  597
- Installing the Bearing Retainer
  598
- Transmission
  599
Xv17Pcv(C)/Xv17Pcmv(C) 2006 Wiring Diagram

604

Yamaha XV1700PCRC Road Star Warrior Owner's Manual (122 pages)

Brand: Yamaha | Category: Motorcycle | Size: 1.19 MB

Table of Contents

7
- Important Manual Information
  5
- Safety Information
  9
  - Safe Riding
    10
  - Safety Information
    11
    
    Protective Apparel
    12
    
    Modifications
    12
    
    Loading and Accessories
    12
    
    Gasoline and Exhaust Gas
    14
    
    Location of Important Labels
    16
  - Description
    19
    
    Left View
    20
    
    Right View
    21
    
    Controls and Instruments
    22
Instrument and Control Functions

23
- Main Switch/Steering Lock
  24
- Instrument and Control Functions
  25
  - Indicator and Warning Lights
    25
  - Speedometer
    26
  - Tachometer Unit
    27
  - Handlebar Switches
    29
  - Clutch Lever
    30
  - Shift Pedal
    30
  - Brake Lever
    31
  - Brake Pedal
    31
  - Fuel Tank Cap
    32
  - Fuel
    32
  - Seat
    34
  - Helmet Holder
    34
  - Adjusting the Front Fork
    35
  - Adjusting the Shock Absorber Assembly
    36
  - Sidestand
    38
  - Ignition Circuit Cut-Off System
    39
- Pre-Operation Checks
  41
  - Pre-Operation Check List
    42
- Operation and Important Riding Points
  45
  - Operation and Important Riding Points
    47
  - Engine Break-In
    50
Periodic Maintenance and Minor Repair

51
Consumer Information

107
- Identification Numbers
  108
- Key Identification Number
  108
- Vehicle Identification Number
  108
- Model Label
  109
- Reporting Safety Defects
  110
- Motorcycle Noise Regulation
  111
- Maintenance Record
  112
- Yamaha Motor Corporation, U.s.a. Street and Enduro Motorcycle Limited Warranty
  114
- Yamaha Extended Service (Y.e.s.)
  116

Yamaha XV1700PCRC Road Star Warrior Supplementary Service Manual (34 pages)

Brand: Yamaha | Category: Motorcycle | Size: 3.56 MB

Table of Contents
7
Specifications
8
General Specifications
8
Engine Specifications
8
Chassis Specifications
8
Electrical Specifications
9
Tightening Torques
9
Chassis Tightening Torques
9
Cable Routing
10
Periodic Checks and Adjustments
18
Introduction
18
Periodic Maintenance Chart for the Emission Control System
18
General Maintenance and Lubrication Chart
19
Chassis
21
Adjusting the Rear Shock Absorber Assembly
21
Chassis
23
Front and Rear Brakes
23
Rear Brake Master Cylinder
23
Rear Shock Absorber and Swingarm
25
Engine
29
Rocker Arms, Push Rods and Valve Lifters
29
Generator and Starter Clutch
31
Stator Coil Assembly
31

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Yamaha XV1700PCRC Road Star Warrior Manuals

Yamaha XV1700PCRC Road Star Warrior Service Manual (606 pages)

Table of Contents

Periodic Checks and Adjustments

Chassis

Engine

Chapter 1 General Information

Motorcycle Identification

Features

Important Information

Checking the Connections

Special Tools

Chapter 2 Specifications

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Conversion Table

General Tightening Torque Specifications

Lubrication Points and Lubricant Types

Engine Oil Lubrication Chart

Engine Oil Flow Diagrams

Transfer Gear Oil Flow Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Seat and Side Covers

Headlight and Meter Assemblies

Battery

Fuel Tank

Air Filter Case

Silencer Air Filter Case

Engine

Chassis

Electrical System

Chapter 4 Chassis

Front Wheel and Brake Discs

Rear Wheel, Brake Disc, and Rear Wheel Pulley

Front and Rear Brakes

Front Fork

Handlebar

Steering Head

Rear Shock Absorber and Swingarm

Chapter 5 Engine

Rocker Arms, Push Rods and Valve Lifters

Camshafts

Cylinder Heads

Valves and Valve Springs

Cylinders and Pistons

Shift Shaft and Stopper Lever

Generator and Starter Clutch

Transfer Gear Case

Crankcase

Engine Oil Pump

Crankshaft and Connecting Rods

Transmission

Chapter 6 Fuel Injection System

Air Induction System

Chapter 7 Electrical System

Electrical Components

Arrangement of the Electrical Components and Couplers

Checking Switch Continuity

Checking the Switches

Checking the Bulbs and Bulb Sockets

Starter Motor

Charging System

Chapter 8 Troubleshooting

Starting Failures

Incorrect Engine Idling Speed

Poor Medium-And-High-Speed Performance

Faulty Gear Shifting

Faulty Clutch

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Xv17Pcv(C)/Xv17Pcmv(C) 2006 Wiring Diagram

Yamaha XV1700PCRC Road Star Warrior Owner's Manual (122 pages)