This document is an assembly manual for the Yamaha XV1700P and XV1700PC motorcycles, model year 2002. It provides detailed instructions for the correct reassembly of the motorcycle prior to delivery to the customer, as well as important technical specifications, usage features, and maintenance procedures.
Function Description
The Yamaha XV1700P and XV1700PC are cruiser-style motorcycles designed for road use. As an assembly manual, its primary function is to guide technicians through the process of putting the motorcycle together from its factory-packed state, ensuring all components are correctly installed and torqued to specification. This includes the assembly of the handlebar, front brake master cylinder, clutch cable, plastic clamps, rear view mirrors, front fender, front wheel, air duct cover, battery, and various covers. The manual also covers essential adjustments and pre-delivery services to ensure the motorcycle is safe and ready for operation.
Important Technical Specifications
The manual provides a comprehensive list of tightening torques for various components, which are crucial for safe and reliable operation. These torques are specified in Newton-meters (Nm), meter-kilograms (m·kg), and foot-pounds (ft·lb).
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Engine:
- Spark plug: M12, 18 Nm (1.8 m·kg, 13 ft·lb)
- Engine oil drain bolt (engine): M14, 43 Nm (4.3 m·kg, 31 ft·lb)
- Engine oil drain bolt (oil tank): M8, 20 Nm (2.0 m·kg, 14 ft·lb)
- Transfer gear oil drain bolt: M8, 18 Nm (1.8 m·kg, 13 ft·lb)
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Chassis:
- Upper bracket and outer tube: M8, 26 Nm (2.6 m·kg, 19 ft·lb)
- Lower bracket and outer tube: M8, 23 Nm (2.3 m·kg, 17 ft·lb)
- Upper bracket and steering shaft: M28, 115 Nm (11.5 m·kg, 85 ft·lb)
- Handlebar holder (lower) and handlebar holder (upper): M8, 28 Nm (2.8 m·kg, 20 ft·lb)
- Ring nut (steering shaft): M30, 4 Nm (0.4 m·kg, 2.9 ft·lb)
- Brake hose joint and lower bracket: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Brake master cylinder reservoir cap: M4, 2 Nm (0.2 m·kg, 1.4 ft·lb)
- Turn signal light bracket and lower bracket: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Turn signal light bracket pinch bolt: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Headlight bracket and lower bracket: M8, 23 Nm (2.3 m·kg, 17 ft·lb)
- Headlight bracket and brake hose joint: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Handlebar holder (lower): M12, 40 Nm (4.0 m·kg, 29 ft·lb)
- Front brake master cylinder: M6, 10 Nm (1.0 m·kg, 7.2 ft·lb)
- Union bolt (brake hose): M10, 32 Nm (3.2 m·kg, 23 ft·lb)
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Engine mounting:
- Spacer bolt: M18, 18 Nm (1.8 m·kg, 13 ft·lb)
- Upper mounting bolt (upper engine bracket and engine): M10, 48 Nm (4.8 m·kg, 35 ft·lb)
- Upper engine bracket and frame: M10, 48 Nm (4.8 m·kg, 35 ft·lb)
- Lower front mounting nut (frame and engine): M10, 100 Nm (10.0 m·kg, 72 ft·lb)
- Lower rear mounting nut (frame and engine): M12, 88 Nm (8.8 m·kg, 64 ft·lb)
- Rear engine bracket and frame: M10, 53 Nm (5.3 m·kg, 38 ft·lb)
- Rear engine bracket and engine: M12, 98 Nm (9.8 m·kg, 71 ft·lb)
- Front engine bracket and frame: M10, 48 Nm (4.8 m·kg, 35 ft·lb)
- Front engine bracket and engine: M12, 88 Nm (8.8 m·kg, 64 ft·lb)
- Transfer gear case and transfer gear case bracket: M10, 63 Nm (6.3 m·kg, 45 ft·lb)
- Transfer gear case bracket and frame: M10, 53 Nm (5.3 m·kg, 38 ft·lb)
- Muffler bracket and frame: M8, 53 Nm (5.3 m·kg, 38 ft·lb)
- Muffler bracket and muffler: M8, 20 Nm (2.0 m·kg, 14 ft·lb)
- Ignition coil: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Swingarm pivot shaft: M18, 125 Nm (12.5 m·kg, 90 ft·lb)
- Relay arm and swingarm: M12, 59 Nm (5.9 m·kg, 43 ft·lb)
- Relay arm and connecting rod: M12, 59 Nm (5.9 m·kg, 43 ft·lb)
- Relay arm and rear shock absorber: M10, 40 Nm (4.0 m·kg, 29 ft·lb)
- Rear shock absorber, connecting rod and frame: M12, 59 Nm (5.9 m·kg, 43 ft·lb)
- Upper drive belt cover and swingarm: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Lower drive belt cover and swingarm: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Rear fender bracket and frame: M10, 40 Nm (4.0 m·kg, 29 ft·lb)
- Rear fender bracket and rear fender: M8, 23 Nm (2.3 m·kg, 17 ft·lb)
- Fuel tank and fuel filter: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Fuel tank bracket and frame: M6, 10 Nm (1.0 m·kg, 7.2 ft·lb)
- Fuel tank and frame: M8, 10 Nm (1.0 m·kg, 7.2 ft·lb)
- Sub fuel tank and frame: M6, 10 Nm (1.0 m·kg, 7.2 ft·lb)
- Seat bracket and frame: M8, 16 Nm (1.6 m·kg, 11 ft·lb)
- Side cover and side cover bracket: M6, 4 Nm (0.4 m·kg, 2.9 ft·lb)
- Side cover bracket and frame: M6, 13 Nm (1.3 m·kg, 9.4 ft·lb)
- Side cover and seat bracket: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Starter relay and battery positive lead: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Starter relay and starter motor lead: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Battery box and frame: M6, 7 Nm (0.7 m·kg, 5.1 ft·lb)
- Battery box bracket and frame: M10, 63 Nm (6.3 m·kg, 45 ft·lb)
- Sidestand and bolt: M12, 122 Nm (12.2 m·kg, 88 ft·lb)
- Sidestand and nut: M12, 88 Nm (8.8 m·kg, 64 ft·lb)
- Footrest bracket and frame: M10, 48 Nm (4.8 m·kg, 35 ft·lb)
- Rear footrest and frame: M10, 48 Nm (4.8 m·kg, 35 ft·lb)
- Front brake master cylinder holder: M6, 10 Nm (1.0 m·kg, 7.2 ft·lb)
- Rear brake master cylinder and rear brake master cylinder bracket: M8, 23 Nm (2.3 m·kg, 17 ft·lb)
- Rear brake master cylinder cover and frame: M8, 23 Nm (2.3 m·kg, 17 ft·lb)
- Rear brake fluid reservoir: M4, 2 Nm (0.2 m·kg, 1.4 ft·lb)
- Union bolt (rear brake hose): M10, 30 Nm (3.0 m·kg, 22 ft·lb)
- Brake rod and rear brake master cylinder: M8, 16 Nm (1.6 m·kg, 11 ft·lb)
- Front wheel axle: M18, 72 Nm (7.2 m·kg, 52 ft·lb)
- Front wheel axle pinch bolt: M8, 23 Nm (2.3 m·kg, 17 ft·lb)
- Rear wheel axle nut: M18, 150 Nm (15.0 m·kg, 110 ft·lb)
- Front brake caliper: M10, 40 Nm (4.0 m·kg, 29 ft·lb)
- Rear brake caliper: M10, 27 Nm (2.7 m·kg, 19 ft·lb)
- Brake disc and wheel: M8, 18 Nm (1.8 m·kg, 13 ft·lb)
- Caliper bleed screw (front): M6, 6 Nm (0.6 m·kg, 4.3 ft·lb)
- Caliper bleed screw (rear): M7, 6 Nm (0.6 m·kg, 4.3 ft·lb)
- Rear wheel sprocket and rear wheel drive hub: M12, 95 Nm (9.5 m·kg, 68 ft·lb)
- Rear brake caliper bracket and swingarm: M10, 30 Nm (3.0 m·kg, 22 ft·lb)
- Front fork guard and front fork: M8, 16 Nm (1.6 m·kg, 11 ft·lb)
- Front fork guard and front fork: M6, 13 Nm (1.3 m·kg, 9.4 ft·lb)
- Front fender and front fork leg: M8, 16 Nm (1.6 m·kg, 11 ft·lb)
- Clip bolt and outer tube: —, 23 Nm (2.3 m·kg, 17 ft·lb)
- Damping rod assembly bolt: —, 40 Nm (4.0 m·kg, 29 ft·lb)
- Reflector bracket (front): M8, 8 Nm (0.8 m·kg, 5.8 ft·lb)
- Footrest bracket and rear brake bracket: M8, 16 Nm (1.6 m·kg, 11 ft·lb)
- Footrest bracket and shift rod bracket: M8, 16 Nm (1.6 m·kg, 11 ft·lb)
- Rear brake bracket and brake pedal: M8, 19 Nm (1.9 m·kg, 13 ft·lb)
- Shift shaft and shift pedal: M6, 12 Nm (1.2 m·kg, 8.7 ft·lb)
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Engine idling speed: 850 – 950 r/min when warm.
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Spark plug: DPR7EA-9 (NGK), X22EPR-U9 (DENSO). Gap: 0.8 – 0.9 mm (0.031 – 0.035 in).
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Fuel: Recommended fuel: Unleaded. Fuel tank capacity (total): 15 L (3.3 Imp gal, 4.0 US gal).
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Valve clearance (cold): IN: 0 – 0.04 mm (0 – 0.0016 in). EX: 0 – 0.04 mm (0 – 0.0016 in).
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Maximum load: 185 kg (408 lb). This includes the total weight of cargo, rider, passenger, and accessories.
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Tire pressure (cold):
- Up to 90 kg (198 lb) load: Front 250 kPa (2.50 kg/cm², 36 psi), Rear 250 kPa (2.50 kg/cm², 36 psi).
- 90 kg (198 lb) ~ Maximum load: Front 250 kPa (2.50 kg/cm², 36 psi), Rear 290 kPa (2.90 kg/cm², 41 psi).
- High-speed riding: Front 250 kPa (2.50 kg/cm², 36 psi), Rear 250 kPa (2.50 kg/cm², 36 psi).
Usage Features
The manual emphasizes several usage features related to proper assembly and adjustment that directly impact the motorcycle's operation and safety.
- Cable Routing: Proper cable routing is critical to assure safe motorcycle operation. The manual provides detailed diagrams and instructions for routing the clutch cable, throttle cables, ECU leads, battery leads, de-compression solenoid lead, speed sensor lead, cylinder identification sensor lead, sidestand switch lead, pickup coil lead, and neutral switch lead. It highlights the importance of leaving sufficient space between the throttle cable holder and the right handlebar switch, and between the brake hose and throttle cable holder.
- Adjustments: Various adjustments are covered to optimize the motorcycle's performance and rider comfort.
- Engine oil level inspection: Requires the motorcycle to be on a level surface.
- Transfer gear oil level inspection: Also requires the motorcycle to be on a level surface.
- Idling speed adjustment: The engine should be warm, and the throttle stop screw is used to adjust the idling speed.
- Throttle cable free play adjustment: Essential for smooth throttle operation and preventing unintended acceleration. Free play should be 4–6 mm (0.16–0.24 in) at the throttle grip flange.
- Front brake adjustment: Involves checking and adjusting the brake lever free play (2–5 mm or 0.08–0.20 in at the brake lever end) and the brake pedal height (80 mm or 3.0 in above the top of the footrest).
- Rear brake light switch adjustment: Ensures the brake light activates correctly when the brake pedal is pressed.
- Clutch adjustment: Involves checking and adjusting the clutch cable free play (10–15 mm or 0.4–0.6 in at the clutch lever end).
- Drive belt slack adjustment: Critical for proper power transfer and longevity of the drive belt. Slack should be 5–7 mm (0.2–0.28 in) at 4.5 kg (10 lbs) of pressure.
- Front fork adjustment: Involves adjusting the spring preload to suit rider preferences and load. Standard position is 5, minimum is 8, and maximum is 1.
- Rear shock absorber adjustment: Allows for adjustment of spring preload to optimize ride comfort and handling. Standard length is 42.5 mm (1.67 in), minimum is 40.5 mm (1.59 in), and maximum is 51.5 mm (2.03 in).
- Headlight beam adjustment: Both vertical and horizontal adjustments are possible to ensure proper illumination and avoid dazzling other road users.
Maintenance Features
The manual outlines several maintenance features, particularly those related to pre-delivery service and ongoing checks.
- Pre-delivery Service: This section details the necessary checks and adjustments to be performed before the motorcycle is delivered to a customer. This includes inspecting fluid levels, brake adjustments, cable routing, and general component integrity.
- Engine Oil Level Inspection: Regular checking of the engine oil level is crucial. The manual specifies the recommended oil (Yamalube 4 (20W40) or SAE 20W40 motor oil) and the procedure for checking the level using the dipstick.
- Transfer Gear Oil Level Inspection: Similar to engine oil, regular inspection of the transfer gear oil level is required. The recommended oil is SAE 80 API "GL-4" Hypoid gear oil.
- Brake Fluid Level Inspection: The manual stresses the importance of checking the brake fluid level in both the front and rear reservoirs. Recommended brake fluid is DOT 4. It also includes a warning about using only designated brake fluid and avoiding mixing different types.
- Air Bleeding (Hydraulic Brake System): Detailed instructions are provided for bleeding air from the hydraulic brake system, a critical procedure if the brake system is disassembled or if the fluid level is very low, to prevent impaired braking performance.
- Battery Inspection and Charging: The manual describes how to check the open-circuit voltage of the battery using a digital voltmeter. It specifies that if the voltage is lower than 12.8 V, the battery must be charged. Warnings are included regarding the dangers of battery electrolyte and the importance of proper ventilation during charging.
- Owner's Tool Kit: The manual lists the contents of the owner's tool kit, which includes essential tools for basic maintenance and adjustments, such as open wrenches, box wrenches, spark plug wrench, screwdrivers, and hexagon wrenches.
Safety Precautions
Throughout the manual, numerous "WARNING" and "CAUTION" advisories are present to ensure the safety of the technician and the future rider.
- WARNING: Indicates a hazard that could result in severe injury or death to the motorcycle operator, a bystander, or a person inspecting or repairing the motorcycle.
- Examples include warnings about proper cable routing, handling brake fluid, bleeding the brake system, securely supporting the motorcycle during adjustments, and handling batteries.
- CAUTION: Indicates special precautions that must be taken to avoid damage to the motorcycle.
- Examples include cautions about cleaning brake discs, avoiding excessive torque on drive belts, and ensuring proper headlight beam adjustment.
This comprehensive manual serves as an indispensable guide for the assembly, initial setup, and basic maintenance of the Yamaha XV1700P and XV1700PC motorcycles, ensuring they meet safety and performance standards before being put into service.
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