Yamaha XV1700P - User Manual

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XV1700P

XV1700PC

SERVICE MANUAL

LIT-11616-15-37 5PX-28197-10

Main Page

General Information5
Specifications5
- Table of Contents6
Periodic Checks and Adjustments5
Chassis5
Engine5
Fuel Injection System5
Electrical System5
Troubleshooting16
Chapter 1 General Information18
Motorcycle Identification18
- Vehicle Identification Number18
- Model Label18
Features19
- Outline19
- Fi System20
- Components22
- Fuel Injection System34
- First Idle Control System45
- Components46
Important Information49
- Preparation for Removal and Disassembly49
- Replacement Parts49
- Gaskets, Oil Seals and O-Rings49
- Lock Washers/Plates and Cotter Pins50
- Bearings and Oil Seals50
- Circlips50
Checking the Connections51
Special Tools52
Chapter 2 Specifications57
Spec57
General Specifications57
Engine Specifications58
Chassis Specifications69
Electrical Specifications73
Conversion Table76
General Tightening Torque Specifications76
Tightening Torques77
Lubrication Points and Lubricant Types83
- Engine83
- Chassis84
Engine Oil Lubrication Chart85
Engine Oil Flow Diagrams86
Transfer Gear Oil Flow Diagrams90
Cable Routing92
Chapter 3 Periodic Checks and Adjustments107
Introduction107
Chk Adj107
Periodic Maintenance Chart for the Emission Control System107
General Maintenance and Lubrication Chart108
Seat and Side Covers110
Headlight and Meter Assemblies111
Battery112
Fuel Tank113
Air Filter Case114
Silencer Air Filter Case115
Engine117
- Adjusting the Valve Clearance117
- Synchronizing the Throttle Bodies121
- Adjusting the Engine Idling Speed123
- Adjusting the Throttle Cable Free Play124
- Checking the Spark Plugs126
- Checking the Ignition Timing128
- Measuring the Compression Pressure129
- Checking the Engine Oil Level132
- Changing the Engine Oil133
- Measuring the Engine Oil Pressure137
- Checking the Transfer Gear Oil Level138
- Changing the Transfer Gear Oil139
- Adjusting the Clutch Cable Free Play141
- Cleaning the Air Filter Elements142
- Checking the Throttle Body Joints143
- Checking the Fuel Hoses143
- Checking the Cylinder Head Breather Hose and Oil Tank Breather Hose144
- Checking the Exhaust System145
Chassis146
- Adjusting the Front Brake146
- Adjusting the Rear Brake147
- Checking the Brake Fluid Level148
- Checking the Front Brake Pads149
- Checking the Rear Brake Pads149
- Adjusting the Rear Brake Light Switch150
- Checking the Front and Rear Brake Hoses150
- Bleeding the Hydraulic Brake System151
- Adjusting the Shift Pedal153
- Adjusting the Drive Belt Slack153
- Checking and Adjusting the Steering Head156
- Checking the Front Fork158
- Adjusting the Front Fork Legs159
- Adjusting the Rear Shock Absorber Assembly160
- Checking the Tires161
- Checking the Wheels164
- Checking and Lubricating the Cables164
- Lubricating the Levers and Pedals165
- Lubricating the Sidestand165
- Lubricating the Rear Suspension165
Electrical System166
- Checking and Charging the Battery166
- Checking the Fuses171
- Replacing the Headlight Bulb174
- Adjusting the Headlight Beam175
- Odometer and Tripmeter176
- Adjusting the Meter Light177
- Adjusting the Clock177
Chapter 4 Chassis178
Front Wheel and Brake Discs178
- Removing the Front Wheel181
- Checking the Front Wheel181
- Checking the Brake Discs183
- Installing the Front Wheel184
- Adjusting the Front Wheel Static Balance186
Chas178
Rear Wheel, Brake Disc, and Rear Wheel Pulley188
- Removing the Rear Wheel194
- Checking the Rear Wheel194
- Checking the Rear Wheel Drive Hub195
- Checking and Replacing the Rear Wheel Pulley195
- Assembling the Rear Wheel195
- Installing the Rear Wheel196
- Adjusting the Rear Wheel Static Balance199
Front and Rear Brakes200
- Front Brake Pads200
- Rear Brake Pads201
- Replacing the Front Brake Pads202
- Replacing the Rear Brake Pads204
- Front Brake Master Cylinder208
- Rear Brake Master Cylinder210
- Removing the Rear Brake Master Cylinder214
- Checking the Front and Rear Brake Master Cylinders214
- Assembling and Installing the Front Brake Master Cylinder215
- Assembling and Installing the Rear Brake Master Cylinder218
- Front Brake Calipers220
- Rear Brake Caliper222
- Disassembling the Front Brake Calipers224
- Disassembling the Rear Brake Caliper225
- Checking the Front and Rear Brake Calipers226
- Assembling and Installing the Front Brake Calipers227
- Assembling and Installing the Rear Brake Caliper229
Front Fork232
- Removing the Front Fork Legs232
- Disassembling the Front Fork Legs233
- Checking the Front Fork Legs237
- Assembling the Front Fork Legs239
- Installing the Front Fork Legs244
Handlebar246
- Removing the Handlebar248
- Checking the Handlebar248
- Installing the Handlebar248
Steering Head252
- Removing the Lower Bracket254
- Checking the Steering Head254
- Installing the Steering Head255
Rear Shock Absorber and Swingarm257
- Handling the Rear Shock Absorber261
- Disposing of a Rear Shock Absorber and Gas Cylinder261
- Removing the Rear Shock Absorber and Swingarm262
- Checking the Rear Shock Absorber263
- Checking the Relay Arm and Connecting Arm263
- Checking the Swingarm263
- Installing the Rear Shock Absorber and Swingarm264
Drive Belt and Drive Sprocket266
- Removing the Drive Belt and Drive Sprocket266
- Checking the Drive Belt267
- Installing the Drive Belt and Drive Sprocket268
Chapter 5 Engine269
- Installing the Engine277
- Installing the Muffler and Exhaust Pipes278
Eng269
Rocker Arms, Push Rods and Valve Lifters279
- Removing the Rocker Arms, Push Rods and Valve Lifters284
- Checking the Rocker Arms and Rocker Arm Shafts284
- Checking the Rocker Arm Bases286
- Checking the Push Rods286
- Checking the Valve Lifters and Valve Lifter Cases286
- Bleeding a Valve Lifter287
- Checking the Push Rod Cover289
- Installing the Valve Lifters289
- Installing the Rocker Arms and Push Rods290
- Installing the Cylinder Head Covers291
- Installing the Camshaft Sprocket Cover and Engine Left Side Cover291
Camshafts293
- Checking the Camshafts296
- Checking the Decompression System298
- Checking the Oil Delivery Pipe298
- Installing the Camshafts299
Cylinder Heads302
- Removing the Cylinder Heads304
- Checking the Cylinder Heads304
- Checking the Oil Delivery Pipe305
- Installing the Cylinder Head305
Valves and Valve Springs307
- Removing the Valves308
- Checking the Valves and Valve Guides309
- Checking the Valve Seats311
- Checking the Valve Springs314
Cylinders and Pistons317
- Removing the Cylinders and Pistons318
- Checking the Cylinders and Pistons319
- Checking the Piston Rings320
- Checking the Piston Pins321
- Installing the Pistons and Cylinders322
Clutch324
- Clutch Cover324
- Clutch325
- Removing the Clutch329
- Removing the Primary Drive Gear330
- Checking the Friction Plates330
- Checking the Clutch Plates330
- Checking the Clutch Plate Spring331
- Checking the Clutch Housing331
- Checking the Clutch Boss331
- Checking the Pressure Plate332
- Checking the Pull Lever Shaft and Pull Rod332
- Checking the Primary Drive332
- Installing the Crankshaft Position Sensor and Pull Lever Shaft332
- Installing the Primary Drive Gear333
- Installing the Clutch334
Shift Shaft and Stopper Lever338
- Checking the Shift Shaft339
- Checking the Stopper Lever339
- Installing the Stopper Lever and Shift Shaft339
Generator and Starter Clutch341
- Stator Coil Assembly341
- Removing the Generator344
- Checking the Starter Clutch344
- Installing the Generator345
Transfer Gear Case347
- Fuel Pump350
- Removing the Fuel Pump351
- Install the Fuel Pump351
- Sub Fuel Tank352
- Removing the Middle Driven Shaft356
- Checking the Middle Drive356
- Checking the Oil Strainer357
- Checking the Oil Pump357
- Checking the Oil Pipe358
- Assembling the Oil Pump358
- Installing the Transfer Gear Case359
Crankcase361
- Disassembling the Crankcase364
- Checking the Crankcase365
- Checking the Bearings and Oil Seals366
- Checking the Oil Delivery Pipe366
- Checking the Engine Oil Pump Drive366
- Assembling the Crankcase367
Engine Oil Pump370
- Checking the Oil Pump373
- Checking the Relief Valve373
- Checking the Oil Strainer374
- Assembling the Oil Pump374
- Installing the Oil Pump375
- Installing the Oil Strainer376
Crankshaft and Connecting Rods377
- Removing the Crankshaft378
- Removing the Connecting Rods378
- Checking the Crankshaft and Connecting Rods378
- Installing the Connecting Rods384
- Installing the Crankshaft386
Transmission387
- Checking the Shift Forks390
- Checking the Shift Drum Assembly391
- Checking the Transmission391
- Installing the Transmission392
- Installing the Shift Forks and Shift Drum Assembly392
Chapter 6 Fuel Injection System394
- Wiring Diagram395
- Ecu's Self-Diagnostic Function397
- Substitute Characteristics Operation Control (Fail-Safe Action)401
- Troubleshooting402
- Throttle Bodies430
- Checking the Injector434
- Checking the Throttle Body434
- Checking the Fuel Pump and Pressure Regulator Operation435
Air Induction System436
- Air Injection436
- Air Cut-Off Valve436
- Air Cut-Off Valve Assembly and Air Induction System Hoses437
- Reed Valves438
- Checking the Pressure Regulator439
- Checking the Air Induction System439
Chapter 7 Electrical System440
Electrical Components440
Elec440
Arrangement of the Electrical Components and Couplers442
Checking Switch Continuity447
Checking the Switches448
Checking the Bulbs and Bulb Sockets450
- Types of Bulbs450
- Checking the Condition of the Bulbs450
- Checking the Condition of the Bulb Sockets452
- CHECKING the Leds453
Ignition System454
- Circuit Diagram454
- Troubleshooting455
Electric Starting System460
- Circuit Diagram460
- Starting Circuit Cut-Off System Operation461
- Troubleshooting462
Starter Motor466
- Checking the Starter Motor469
- Assembling the Starter Motor471
Charging System473
- Circuit Diagram473
- Troubleshooting474
- Circuit Diagram476
- Troubleshooting477
- Checking the Lighting System478
Signaling System482
- Circuit Diagram482
- Troubleshooting484
- Checking the Signaling System485
Fuel Injection System492
- Circuit Diagram492
- Troubleshooting494
- Checking the Fuel Pump502
- Checking and Adjusting the Throttle Position Sensor502
Chapter 8506
- Engine506
- Fuel System506
Starting Failures506
Trbl Shtg507
- Electrical Systems507
Incorrect Engine Idling Speed507
- Engine507
- Fuel System507
Poor Medium-And-High-Speed Performance508
- Engine508
- Fuel System508
Faulty Gear Shifting508
- Shifting Is Difficult508
- Shift Pedal Does Not Move508
- Jumps out of Gear508
Faulty Clutch508
- Clutch Slips508
- Clutch Drags508
Overheating509
- Engine509
- Fuel System509
- Chassis509
- Electrical Systems509
Poor Braking Performance509
Faulty Front Fork Legs509
- Leaking Oil509
- Malfunction509
Unstable Handling510
Faulty Lighting or Signaling System511
- Headlight Does Not Come on511
- Headlight Bulb Burnt out511
- Tail/Brake Light Does Not Come on511
- Tail/Brake Light Led Burnt out511
- Turn Signal Does Not Come on511
- Turn Signal Blinks Slowly511
- Turn Signal Remains Lit511
- Turn Signal Blinks Quickly511
- Horn Does Not Sound511

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Yamaha XV1700P Specifications

General

Displacement	1670 cc
Compression Ratio	8.3:1
Fuel System	Electronic Fuel Injection
Ignition	TCI
Transmission	5-speed
Final Drive	Belt
Front Suspension	Telescopic fork
Rear Suspension	Swingarm
Front Brake	Dual disc
Rear Brake	Single disc
Bore x Stroke	97.0mm x 113.0mm
Front Tire	130/90-16
Height	1145mm
Fuel Capacity	17.0 liters
Maximum Torque	140 Nm