Yamaha XV1700P XV1700PC Service Manual – PDF DOWNLOAD
DESCRIPTION:
Yamaha XV1700P XV1700PC Service Manual – PDF DOWNLOAD
FOREWORD:
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers 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 to 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 deal- ers and will appear in future editions of this manual where applicable.
TABLE OF CONTENTS:
Yamaha XV1700P XV1700PC Service Manual – PDF DOWNLOAD
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION1-1
VEHICLE IDENTIFICATION NUMBER 1-1
MODEL LABEL1-1
FEATURES1-2
OUTLINE 1-2
FI SYSTEM1-3
COMPONENTS1-5
FUEL INJECTION SYSTEM1-17
FIRST IDLE CONTROL SYSTEM 1-28
COMPONENTS1-29
IMPORTANT INFORMATION1-32
PREPARATION FOR REMOVAL AND DISASSEMBLY1-32
REPLACEMENT PARTS1-32
GASKETS, OIL SEALS AND O-RINGS 1-32
LOCK WASHERS/PLATES AND COTTER PINS 1-33
BEARINGS AND OIL SEALS 1-33
CIRCLIPS 1-33
CHECKING THE CONNECTIONS 1-34
SPECIAL TOOLS 1-35
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS2-1
ENGINE SPECIFICATIONS 2-2
CHASSIS SPECIFICATIONS 2-13
ELECTRICAL SPECIFICATIONS 2-17
CONVERSION TABLE 2-20
GENERAL TIGHTENING TORQUE SPECIFICATIONS 2-20
TIGHTENING TORQUES 2-21
ENGINE TIGHTENING TORQUES2-21
CHASSIS TIGHTENING TORQUES2-24
LUBRICATION POINTS AND LUBRICANT TYPES2-27
ENGINE 2-27
CHASSIS 2-28
ENGINE OIL LUBRICATION CHART 2-29
ENGINE OIL FLOW DIAGRAMS 2-30
TRANSFER GEAR OIL FLOW DIAGRAMS 2-34
CABLE ROUTING 2-36
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION3-1
PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART3-2
SEAT AND SIDE COVERS 3-4
HEADLIGHT AND METER ASSEMBLIES3-5
BATTERY 3-6
FUEL TANK3-7
AIR FILTER CASE3-8
SILENCER AIR FILTER CASE 3-9
ENGINE3-11
ADJUSTING THE VALVE CLEARANCE3-11
SYNCHRONIZING THE THROTTLE BODIES3-15
ADJUSTING THE ENGINE IDLING SPEED 3-17
ADJUSTING THE THROTTLE CABLE FREE PLAY3-18
CHECKING THE SPARK PLUGS 3-20
CHECKING THE IGNITION TIMING 3-22
MEASURING THE COMPRESSION PRESSURE 3-23
CHECKING THE ENGINE OIL LEVEL3-26
CHANGING THE ENGINE OIL3-27
MEASURING THE ENGINE OIL PRESSURE 3-31
CHECKING THE TRANSFER GEAR OIL LEVEL 3-32
CHANGING THE TRANSFER GEAR OIL3-33
ADJUSTING THE CLUTCH CABLE FREE PLAY 3-35
CLEANING THE AIR FILTER ELEMENTS 3-36
CHECKING THE THROTTLE BODY JOINTS3-37
CHECKING THE FUEL HOSES3-37
CHECKING THE CYLINDER HEAD BREATHER HOSE AND
OIL TANK BREATHER HOSE3-38
CHECKING THE EXHAUST SYSTEM3-39
CHASSIS 3-40
ADJUSTING THE FRONT BRAKE3-40
ADJUSTING THE REAR BRAKE 3-41
CHECKING THE BRAKE FLUID LEVEL3-42
CHECKING THE FRONT BRAKE PADS 3-43
CHECKING THE REAR BRAKE PADS3-43
ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-44
CHECKING THE FRONT AND REAR BRAKE HOSES3-44
BLEEDING THE HYDRAULIC BRAKE SYSTEM3-45
ADJUSTING THE SHIFT PEDAL 3-47
ADJUSTING THE DRIVE BELT SLACK 3-47
CHECKING AND ADJUSTING THE STEERING HEAD 3-50
CHECKING THE FRONT FORK 3-52
ADJUSTING THE FRONT FORK LEGS 3-53
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-54
CHECKING THE TIRES 3-55
CHECKING THE WHEELS 3-58
CHECKING AND LUBRICATING THE CABLES3-58
LUBRICATING THE LEVERS AND PEDALS 3-59
LUBRICATING THE SIDESTAND3-59
LUBRICATING THE REAR SUSPENSION3-59
ELECTRICAL SYSTEM3-60
CHECKING AND CHARGING THE BATTERY3-60
CHECKING THE FUSES3-65
REPLACING THE HEADLIGHT BULB3-68
ADJUSTING THE HEADLIGHT BEAM 3-69
INSTRUMENT FUNCTIONS3-70
ODOMETER AND TRIPMETER3-70
ADJUSTING THE METER LIGHT 3-71
ADJUSTING THE CLOCK3-71
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISCS 4-1
REMOVING THE FRONT WHEEL4-4
CHECKING THE FRONT WHEEL 4-4
CHECKING THE BRAKE DISCS 4-6
INSTALLING THE FRONT WHEEL 4-7
ADJUSTING THE FRONT WHEEL STATIC BALANCE4-9
REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY4-11
REMOVING THE REAR WHEEL 4-17
CHECKING THE REAR WHEEL4-17
CHECKING THE REAR WHEEL DRIVE HUB 4-18
CHECKING AND REPLACING THE REAR WHEEL PULLEY4-18
ASSEMBLING THE REAR WHEEL 4-18
INSTALLING THE REAR WHEEL4-19
ADJUSTING THE REAR WHEEL STATIC BALANCE4-22
FRONT AND REAR BRAKES4-23
FRONT BRAKE PADS 4-23
REAR BRAKE PADS4-24
REPLACING THE FRONT BRAKE PADS 4-25
REPLACING THE REAR BRAKE PADS4-27
FRONT BRAKE MASTER CYLINDER 4-30
REAR BRAKE MASTER CYLINDER 4-33
REMOVING THE FRONT BRAKE MASTER CYLINDER 4-37
REMOVING THE REAR BRAKE MASTER CYLINDER4-37
CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS4-37
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER4-38
ASSEMBLING AND INSTALLING THE REAR BRAKE
MASTER CYLINDER4-41
FRONT BRAKE CALIPERS 4-43
REAR BRAKE CALIPER 4-45
DISASSEMBLING THE FRONT BRAKE CALIPERS4-47
DISASSEMBLING THE REAR BRAKE CALIPER4-48
CHECKING THE FRONT AND REAR BRAKE CALIPERS4-49
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 4-50
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER 4-52
FRONT FORK4-55
REMOVING THE FRONT FORK LEGS 4-58
DISASSEMBLING THE FRONT FORK LEGS 4-58
CHECKING THE FRONT FORK LEGS4-60
ASSEMBLING THE FRONT FORK LEGS 4-62
INSTALLING THE FRONT FORK LEGS4-67
HANDLEBAR4-69
REMOVING THE HANDLEBAR 4-71
CHECKING THE HANDLEBAR4-71
INSTALLING THE HANDLEBAR4-71
STEERING HEAD4-75
REMOVING THE LOWER BRACKET4-77
CHECKING THE STEERING HEAD 4-77
INSTALLING THE STEERING HEAD 4-78
REAR SHOCK ABSORBER AND SWINGARM 4-80
HANDLING THE REAR SHOCK ABSORBER 4-84
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER4-84
REMOVING THE REAR SHOCK ABSORBER AND SWINGARM4-85
CHECKING THE REAR SHOCK ABSORBER4-86
CHECKING THE RELAY ARM AND CONNECTING ARM 4-86
CHECKING THE SWINGARM 4-86
INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM 4-87
DRIVE BELT AND DRIVE SPROCKET 4-89
REMOVING THE DRIVE BELT AND DRIVE SPROCKET4-90
CHECKING THE DRIVE BELT4-90
INSTALLING THE DRIVE BELT AND DRIVE SPROCKET 4-91
CHAPTER 5
ENGINE
ENGINE5-1
INSTALLING THE ENGINE5-9
INSTALLING THE MUFFLER AND EXHAUST PIPES5-10
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 5-11
REMOVING THE ROCKER ARMS, PUSH RODS AND
VALVE LIFTERS5-16
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS5-16
CHECKING THE ROCKER ARM BASES 5-18
CHECKING THE PUSH RODS 5-18
CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES5-18
BLEEDING A VALVE LIFTER 5-19
CHECKING THE PUSH ROD COVER5-21
INSTALLING THE VALVE LIFTERS 5-21
INSTALLING THE ROCKER ARMS AND PUSH RODS5-22
INSTALLING THE CYLINDER HEAD COVERS 5-23
INSTALLING THE CAMSHAFT SPROCKET COVER AND
ENGINE LEFT SIDE COVER 5-23
CAMSHAFTS5-25
REMOVING THE CAMSHAFTS5-27
CHECKING THE CAMSHAFTS 5-28
CHECKING THE DECOMPRESSION SYSTEM5-30
CHECKING THE OIL DELIVERY PIPE5-30
INSTALLING THE CAMSHAFTS 5-31
CYLINDER HEADS 5-34
REMOVING THE CYLINDER HEADS 5-36
CHECKING THE CYLINDER HEADS 5-36
CHECKING THE OIL DELIVERY PIPE5-37
INSTALLING THE CYLINDER HEAD 5-37
VALVES AND VALVE SPRINGS 5-39
REMOVING THE VALVES 5-40
CHECKING THE VALVES AND VALVE GUIDES5-41
CHECKING THE VALVE SEATS 5-43
CHECKING THE VALVE SPRINGS5-46
INSTALLING THE VALVES5-47
CYLINDERS AND PISTONS5-49
REMOVING THE CYLINDERS AND PISTONS 5-50
CHECKING THE CYLINDERS AND PISTONS5-51
CHECKING THE PISTON RINGS5-52
CHECKING THE PISTON PINS5-53
INSTALLING THE PISTONS AND CYLINDERS5-54
CLUTCH5-56
CLUTCH COVER 5-56
CLUTCH 5-59
REMOVING THE CLUTCH 5-61
REMOVING THE PRIMARY DRIVE GEAR 5-62
CHECKING THE FRICTION PLATES5-62
CHECKING THE CLUTCH PLATES 5-62
CHECKING THE CLUTCH PLATE SPRING5-63
CHECKING THE CLUTCH HOUSING 5-63
CHECKING THE CLUTCH BOSS 5-63
CHECKING THE PRESSURE PLATE 5-64
CHECKING THE PULL LEVER SHAFT AND PULL ROD5-64
CHECKING THE PRIMARY DRIVE 5-64
INSTALLING THE CRANKSHAFT POSITION SENSOR AND
PULL LEVER SHAFT 5-64
INSTALLING THE PRIMARY DRIVE GEAR 5-65
INSTALLING THE CLUTCH 5-66
SHIFT SHAFT AND STOPPER LEVER5-70
CHECKING THE SHIFT SHAFT 5-71
CHECKING THE STOPPER LEVER5-71
INSTALLING THE STOPPER LEVER AND SHIFT SHAFT5-71
GENERATOR AND STARTER CLUTCH5-73
STATOR COIL ASSEMBLY 5-73
GENERATOR AND STARTER CLUTCH 5-75
REMOVING THE GENERATOR 5-76
CHECKING THE STARTER CLUTCH 5-76
INSTALLING THE GENERATOR5-77
TRANSFER GEAR CASE 5-79
FUEL PUMP 5-82
REMOVING THE FUEL PUMP 5-83
INSTALL THE FUEL PUMP 5-83
SUB FUEL TANK5-84
REMOVING THE MIDDLE DRIVEN SHAFT 5-88
CHECKING THE MIDDLE DRIVE 5-88
CHECKING THE OIL STRAINER5-89
CHECKING THE OIL PUMP 5-89
CHECKING THE OIL PIPE5-90
ASSEMBLING THE OIL PUMP5-90
INSTALLING THE TRANSFER GEAR CASE 5-91
CRANKCASE 5-93
DISASSEMBLING THE CRANKCASE5-96
CHECKING THE CRANKCASE 5-97
CHECKING THE BEARINGS AND OIL SEALS 5-98
CHECKING THE OIL DELIVERY PIPE5-98
CHECKING THE ENGINE OIL PUMP DRIVE5-98
ASSEMBLING THE CRANKCASE5-99
ENGINE OIL PUMP 5-102
CHECKING THE OIL PUMP 5-105
CHECKING THE RELIEF VALVE 5-105
CHECKING THE OIL STRAINER5-106
ASSEMBLING THE OIL PUMP5-106
INSTALLING THE OIL PUMP 5-107
INSTALLING THE OIL STRAINER5-108
CRANKSHAFT AND CONNECTING RODS5-109
REMOVING THE CRANKSHAFT5-110
REMOVING THE CONNECTING RODS5-110
CHECKING THE CRANKSHAFT AND CONNECTING RODS 5-110
INSTALLING THE CONNECTING RODS5-116
INSTALLING THE CRANKSHAFT 5-118
TRANSMISSION5-119
CHECKING THE SHIFT FORKS5-122
CHECKING THE SHIFT DRUM ASSEMBLY 5-123
CHECKING THE TRANSMISSION 5-123
INSTALLING THE TRANSMISSION 5-124
INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY5-124
CHAPTER 6
FUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM6-1
WIRING DIAGRAM6-2
ECU’S SELF-DIAGNOSTIC FUNCTION6-4
SUBSTITUTE CHARACTERISTICS OPERATION CONTROL
(FAIL-SAFE ACTION)6-8
TROUBLESHOOTING6-9
THROTTLE BODIES 6-37
CHECKING THE INJECTOR6-41
CHECKING THE THROTTLE BODY 6-41
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION6-42
AIR INDUCTION SYSTEM 6-43
AIR INJECTION6-43
AIR CUT-OFF VALVE 6-43
AIR CUT-OFF VALVE ASSEMBLY AND
AIR INDUCTION SYSTEM HOSES6-44
REED VALVES6-45
CHECKING THE PRESSURE REGULATOR6-46
CHECKING THE AIR INDUCTION SYSTEM6-46
CHAPTER 7
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS7-1
ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND
COUPLERS 7-3
CHECKING SWITCH CONTINUITY7-8
CHECKING THE SWITCHES7-10
CHECKING THE BULBS AND BULB SOCKETS 7-12
TYPES OF BULBS 7-12
CHECKING THE CONDITION OF THE BULBS7-12
CHECKING THE CONDITION OF THE BULB SOCKETS7-14
CHECKING THE LEDs7-15
IGNITION SYSTEM7-16
CIRCUIT DIAGRAM 7-16
TROUBLESHOOTING7-17
ELECTRIC STARTING SYSTEM 7-22
CIRCUIT DIAGRAM 7-22
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION 7-23
TROUBLESHOOTING7-24
STARTER MOTOR7-28
CHECKING THE STARTER MOTOR 7-31
ASSEMBLING THE STARTER MOTOR 7-33
CHARGING SYSTEM7-35
CIRCUIT DIAGRAM 7-35
TROUBLESHOOTING7-36
LIGHTING SYSTEM 7-38
CIRCUIT DIAGRAM 7-38
TROUBLESHOOTING7-39
CHECKING THE LIGHTING SYSTEM7-40
SIGNALING SYSTEM7-44
CIRCUIT DIAGRAM 7-44
TROUBLESHOOTING7-46
CHECKING THE SIGNALING SYSTEM 7-47
FUEL INJECTION SYSTEM7-54
CIRCUIT DIAGRAM 7-54
TROUBLESHOOTING7-56
CHECKING THE FUEL PUMP 7-64
CHECKING AND ADJUSTING
THE THROTTLE POSITION SENSOR 7-64
CHAPTER 8
TROUBLESHOOTING
STARTING FAILURES8-1
ENGINE8-1
FUEL SYSTEM8-1
ELECTRICAL SYSTEMS 8-2
INCORRECT ENGINE IDLING SPEED8-2
ENGINE8-2
FUEL SYSTEM8-2
ELECTRICAL SYSTEMS 8-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 8-3
ENGINE8-3
FUEL SYSTEM8-3
FAULTY GEAR SHIFTING8-3
SHIFTING IS DIFFICULT 8-3
SHIFT PEDAL DOES NOT MOVE 8-3
JUMPS OUT OF GEAR8-3
FAULTY CLUTCH 8-3
CLUTCH SLIPS 8-3
CLUTCH DRAGS 8-3
OVERHEATING8-4
ENGINE8-4
FUEL SYSTEM8-4
CHASSIS8-4
ELECTRICAL SYSTEMS 8-4
POOR BRAKING PERFORMANCE8-4
FAULTY FRONT FORK LEGS8-4
LEAKING OIL 8-4
MALFUNCTION8-4
UNSTABLE HANDLING8-5
FAULTY LIGHTING OR SIGNALING SYSTEM8-6
HEADLIGHT DOES NOT COME ON 8-6
HEADLIGHT BULB BURNT OUT8-6
TAIL/BRAKE LIGHT DOES NOT COME ON 8-6
TAIL/BRAKE LIGHT LED BURNT OUT 8-6
TURN SIGNAL DOES NOT COME ON8-6
TURN SIGNAL BLINKS SLOWLY8-6
TURN SIGNAL REMAINS LIT 8-6
TURN SIGNAL BLINKS QUICKLY 8-6
HORN DOES NOT SOUND 8-6
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PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]