XV17AS(C) XV17ASS(C) XV17ATS(C) SUPPLEMENTARY SERVICE MANUAL LIT-11616-17-09 4WM-28197-E1
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XV17AS(C)/XV17ASS(C)/XV17ATS(C). For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XV16AL/XV16ALC/XV16ATL/XV16ATLC SERVICE MANUAL: LIT-11616-12-56 (4WM-28197-E0) XV17AS(C)/XV17ASS(C)/XV17ATS(C) SUPPLEMENTARY SERVICE MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. First Edition, May 2003 All rights reserved.
EAS00003 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers 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.
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. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
1 SYMBOLS 2 GEN INFO The following symbols are not relevant to every vehicle. Symbols 1 to 8 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Carburetor 7 Electrical system 8 Troubleshooting CHAS 5 6 ENG CARB 7 8 – ELEC TRBL SHTG + 9 Symbols 9 to F indicate the following.
CONTENTS SPECIFICATIONS ............................................................................................1 GENERAL SPECIFICATIONS ..................................................................1 ENGINE SPECIFICATIONS ......................................................................2 CHASSIS SPECIFICATIONS ....................................................................6 ELECTRICAL SPECIFICATIONS ...........................................................10 TIGHTENING TORQUES .........
CARBURETOR ...............................................................................................71 AIR INDUCTION SYSTEM ......................................................................71 AIR INDUCTION SYSTEM DIAGRAMS .............................................
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo, rider, passenger, and accessories) Standard Limit 5VN1 (XV17A for USA) 5VN2 (XV17A for California) 5VN6 (XV17A for CDN) 5VR1 (XV17AS for USA) 5VR2 (XV17AS for California) 5VR3 (XV17AS for CDN) 5VP1 (
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Standard Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Camshafts Drive system Crankcase hole inside diameter Camshaft cover hole inside diameter Camshaft journal diameter (crankcase side) Camshaft journal diameter (camshaft cover side) Camshaft to crankcase clearance Camshaft to camshaft cover clearance Camsha
ENGINE SPECIFICATIONS Item Standard SPEC Limit Camshaft exhaust cam dimensions A B Measurement A Measurement B 38.236 ~ 38.336 mm (1.5054 ~ 1.5093 in) 38.136 mm (1.5014 in) 32.013 ~ 32.113 mm (1.2604 ~ 1.2643 in) 31.913 mm (1.2564 in) Rocker arms, rocker arm shafts Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 18.036 mm (0.7101 in) Rocker arm shaft outside diameter 17.976 ~ 17.991 mm (0.7077 ~ 0.7083 in) ---Rocker arm to rocker arm shaft clear- 0.009 ~ 0.042 mm (0.0004 ~ 0.
ENGINE SPECIFICATIONS Item Standard Pistons Piston-to-cylinder clearance SPEC Limit 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm (0.006 in) 96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in) ---- Diameter D H D Height H Piston pin bore (in the piston) Diameter 5 mm (0.20 in) ---- 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm (0.8679 in) 1.0 mm (0.04 in) ---- Offset Piston pins Outside diameter Piston pin-to-piston pin bore clearance Piston rings Top ring 21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in) 21.
ENGINE SPECIFICATIONS Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear Maximum main axle runout Maximum drive axle runout Fuel pump Pump type Model (manufacturer) Output pressure Carburetor Model (manufacturer) × quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet 1 Pilo
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Maximum radial wheel runout Standard Cast wheel Spoke wheel (XV17A for CDN) ------- 16M/C × MT3.00 Aluminum Steel (XV17A for CDN) 140 mm (5.51 in) ------------- ---- 1 mm (0.04 in) 2 mm (0.08 in) (XV17A for CDN) 0.5 mm (0.02 in) 2 mm (0.
CHASSIS SPECIFICATIONS Item Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 kg (198 lb) ~ Maximum load* High-speed riding * Load is the total weight of the cargo, rider, passenger and accessories. Minimum tire tread depth Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 90 kg (198 lb) ~ Maximum load* High-speed riding * Load is the total weight of the cargo, rider, passenger and accessories.
CHASSIS SPECIFICATIONS Item Front brakes Brake type Operation Brake lever free play (lever end) Recommended fluid Brake discs Diameter × thickness Minimum thickness Maximum deflection Standard Dual-disc brake Right-hand operation 2 ~ 5 mm (0.08 ~ 0.20 in) DOT 4 298 × 5 mm (11.7 × 0.
CHASSIS SPECIFICATIONS Item Drive belt Model (manufacturer) Drive belt slack (on a sidestand) Drive belt slack (on a suitable stand) Standard UBD-0681 6 ~ 8 mm (0.24 ~ 0.31 in) 7 ~ 9 mm (0.28 ~ 0.
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system type Ignition timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Bulbs (voltage/wattage × quantity) Headlight Tail/brake light Front turn signal/position light Rear turn signal light Licence plate light Meter light Neutral indicator l
TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Cylinder head Rocker arm base Rocker arm base Front cylinder camshaft end cover Carburetor joint clamp Exhaust pipe Muffler Muffler clamp Generator rotor Pickup coil rotor Clutch boss Pull lever Fastener Thread Q’ty size Tightening torque Nm m · kgf ft · lb Nut Bolt Bolt Bolt Screw Nut Bolt Bolt Bolt Bolt Nut Bolt M12 M8 M6 M5 M4 M8 M10 M8 M12 M12 M20 M6 8 4 8 2 1 4 2 2 1 1 1 1 60 24 10 7 4 20 35 20 80 100 105 12 6.0 2.4 1.
TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item Thread size Upper bracket and inner tube Handlebar holder (lower) and handlebar holder (upper) Throttle cable adjusting nut and locknut Engine mounting: Lower front mounting bolt Lower rear mounting bolt Transfer gear case stay and frame Muffler stay and frame Fuel sender and fuel tank Rear fender side mold and rear fender stay Sidestand bolt Sidestand nut Rear brake fluid reservoir Grip end – 12 – Tightening torque Nm m · kgf ft · lb M6 18 1.
CABLE ROUTING SPEC EB206000 CABLE ROUTING 1 Right handlebar switch lead 2 Throttle cables 3 Brake hoses 4 Clutch cable 5 Left handlebar switch lead 6 Air induction system vacuum hose 7 Rectifier/regulator 8 Rear brake light switch lead È To engine É Route the rear brake light switch lead in front of the rectifier/regulator bracket on the frame. Ê To rear brake light switch Ë Fasten the rear brake light switch lead with the plastic holder.
CABLE ROUTING 1 Rectifier/regulator lead 2 Rear brake light switch lead 3 Wire harness 4 Seat lock cable 5 Throttle position sensor coupler 6 Carburetor heater coupler 7 Air induction system vacuum hose 8 Fuel pump lead 9 Spark plug cap #1 0 Spark plug cap #3 A Horn B Horn lead C Starter motor lead D Clutch cable Ê 4 Ë É Ì Í 5 6 3 È 2 1 B A Ò Ó È Ô Ò D Ñ C 6 Ñ 8 5 SPEC Ö Ð B A 0 Õ B A – 14 – Î Ï 7 8 9
CABLE ROUTING Ì Fasten the air induction system vacuum hose and spark plug lead #2 with the plastic holder. Í Fasten the wire harness, seat lock cable, spark plug lead #1, and spark plug lead #2 to the engine bracket with the plastic band. Î Fasten the spark plug lead #1 and spark plug lead #2 with the plastic holder. Ï Fasten the wire harness, seat lock cable, and spark plug lead #1 with the plastic band. È Fasten the rectifier/regulator lead and rear brake light switch lead with the plastic holders.
CABLE ROUTING Ö Fasten the fuel pump lead with the plastic holder. Ð Fasten the horn lead and starter motor lead to the frame with the plastic locking tie. Ñ Fasten the starter motor lead with the plastic holders. Ò Fasten the clutch cable with the plastic holders. Ó To air cut-off valve Ô To engine Õ Fasten the throttle position sensor lead, carburetor heater lead, and fuel pump lead to the fuel pump bracket with the plastic locking tie.
CABLE ROUTING 1 Wire harness 2 Spark plug cap #1 3 Fuel sender lead 4 Negative battery lead 5 Positive battery lead 6 Tail/brake light lead 7 Starter relay 8 Thermo switch 9 Starter motor lead 0 Fuel tank breather hose A Horn 1 SPEC B Pickup coil lead C Sidestand switch lead D Horn lead E Decompression solenoid lead F Stator coil lead G Neutral switch lead H Speed sensor lead I Clutch cable 2 É 3 Ê Ë 56 Ì 4 È Í Î Ï A I Ô H G F E 7 8 9 B Ð D Ó C Ó Ò B Ñ A 0 9D C Õ A – 17 – B
CABLE ROUTING Í 25 ~ 35 mm (0.98 ~ 1.38 in) Î Fasten the tail/brake light lead with the plastic holders. Ï Pass the positive battery lead through the hole in the battery box. Ð Fasten the sidestand switch lead, horn lead, starter motor lead, and pickup coil lead with the plastic holder. Ñ Fasten the pickup coil lead with the metal holder. È To fuel sender É Fasten the wire harness and seat lock cable to the frame with the plastic band.
CABLE ROUTING SPEC Ò Fasten the speed sensor lead, decompression solenoid lead, pickup coil lead, neutral switch lead, stator coil lead, sidestand switch lead, and horn lead with the plastic holder. Ó Fasten the starter motor lead, sidestand switch lead, and horn lead to the frame with the plastic locking ties. Ô Fasten the clutch cable to the oil delivery pipe with the plastic holder. Õ Attach the plastic holder to the curved section of the oil delivery pipe.
SPEC CABLE ROUTING 1 Turn signal relay 2 Relay unit 3 Battery 4 Oil tank breather hose 5 Fuel tank breather hose 6 Meter assembly lead 7 Throttle cables 8 Right handlebar switch lead 9 Main switch lead 0 Spark plug cap #4 A Spark plug cap #2 B Rear brake light switch lead C Sidestand switch coupler D Pickup coil lead E Horn leads F Starter motor lead G Sidestand switch lead H Decompression solenoid lead I Stator coil lead J Rollover valve 7 6 5 2 3 4 8 É È Ê 9 0 A 1 A B Ì Ë Í 5 Î J Ï I H Ñ
SPEC CABLE ROUTING Ð To decompression solenoid Ñ To speed sensor È Fasten the fuel tank breather hose with the plastic holder. É Fasten the throttle cables and fuel tank breather hose with the plastic holder. Ê Fasten the throttle cables with the plastic holder.
CABLE ROUTING 1 Left handlebar switch lead 2 Throttle cables 3 Right handlebar switch lead 4 Fuel tank breather hose 5 Oil tank breather hose 6 Relay unit 7 Turn signal relay 8 Tail/brake light and rear turn signal light sub-wire harness coupler 9 Thermo switch 0 Fuse box SPEC A Fuel sender lead B Air induction system vacuum hose C Solenoid valve lead (for California) D Spark plug lead #4 E Spark plug lead #2 F Spark plug lead #1 G Spark plug lead #3 É È 2 1 3 C 4 B G A D Ê Ð 5 Ñ 0 Ï 6 7 Î 9 Ë
CABLE ROUTING È Fasten the left handlebar switch lead with the plastic holders. É Fasten the right handlebar switch lead with the plastic holders. Ê To engine Ë Fasten the wire harness with the plastic holder. Ì Align the yellow tape on the wire harness with the hole in battery box, as shown. Í Insert the negative battery lead coupler into the slit in the battery band. SPEC Î Route the starter motor lead between the battery box and plastic bracket.
CABLE ROUTING SPEC Evaporative emission control system (for California) 1 Compensator 2 Compensator breather hose 3 3-way-joint-to-compensator hose 4 Main switch 5 Fuel tank breather hose 6 Rollover valve 7 Rollover-valve-to-3-way-joint hose 8 Surge-tank-to-3-way-joint hose 9 3-way joint 0 3-way-joint-to-charcoal-canister hose A Charcoal canister B Carburetor-to-charcoal-canister hose C Solenoid-valve-to-3-way-joint hose D Solenoid-valve-to-air-filter-case hose E Solenoid valve 1 È 23 É Ê 4 5 Ë 1 3
CABLE ROUTING È Fasten the 3-way-joint-to-compensator hose with the plastic holder. É To solenoid valve Ê Fasten the compensator breather hose and 3way-joint-to-compensator hose with the plastic holder. Ë Fasten the compensator breather hose with the plastic holder. Ì Fasten the clutch cable and rollover-valve-to-3way-joint hose with the plastic holders. 1 SPEC Í Fasten the starter motor lead and horn lead with the plastic holder.
CABLE ROUTING 1 Carburetor-to-surge-tank hose 2 3-way-joint-to-surge-tank hose 3 Surge tank 4 Surge-tank-to-3-way-joint hose 5 Carburetor-to-charcoal-canister hose 6 Solenoid valve 7 3-way-joint 7 2 2 3 6 1 5 3 4 A B B A – 26 – 1 SPEC
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM/GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work.
GENERAL MAINTENANCE AND LUBRICATION CHART No. ITEM 5 * Brake hoses ROUTINE CHK ADJ INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) or or or or or 6 months 12 months 18 months 24 months 30 months √ • Check for cracks or damage. √ √ √ √ Every 4 years • Replace. (See NOTE.) 6 * Wheels • Check runout and for damage. • Replace if necessary.
GENERAL MAINTENANCE AND LUBRICATION CHART CHK ADJ NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. NOTE: ● The air filter needs more frequent service if you are riding in unusually wet or dusty areas. ● Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
SEATS AND SIDE COVERS CHK ADJ SEATS AND SIDE COVERS Order 1 2 3 4 Job/Part Q’ty Remarks Removing the seats and side covers Remove the parts in the order listed. Rider seat 1 Passenger seat 1 Left side cover 1 Right side cover 1 For installation, reverse the removal procedure.
FUEL TANK CHK ADJ EAS00040 FUEL TANK T. R. 7 Nm (0.7 m • kg, 5.1 ft • Ib) 1 2 6 1 3 5 4 Order 1 2 3 4 Job/Part Removing the fuel tank Rider seat Meter assembly Meter assembly coupler Fuel tank breather hose Fuel hose Q’ty 1 2 1 1 Remarks Remove the parts in the order listed. Refer to “SEATS AND SIDE COVERS”. Disconnect. Disconnect. NOTE: Before disconnecting the fuel hose, set the fuel cock to “OFF”. 5 6 Fuel sender coupler Fuel tank 1 1 Disconnect.
FRONT WHEEL AND BRAKE DISCS CHAS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order 1 2 3 4 5 6 7 Job/Part Removing the front wheel and brake discs Reflector (left and right) Brake caliper (left and right) Wheel axle pinch bolt Front wheel axle Front wheel Collar (left and right) Brake disc (left and right) Q’ty Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2 2 1 1 1 2 2 Loosen.
REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY CHAS EAS00550 REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY Order Job/Part Removing the rear wheel Q’ty Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY Order 7 8 9 10 11 12 Job/Part Right adjusting plate Left adjusting plate Rear wheel axle Rear wheel Collar (left and right) Brake caliper bracket Q’ty 1 1 1 1 2 1 CHAS Remarks For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 1 2 T. R. T. R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 7 40 Nm (4.0 m • kg, 29 ft • Ib) 2 6 6 7 4 5 3 Order 1 2 3 4 5 6 7 Job/Part Removing the front brake pads Reflector Brake caliper bolt Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
FRONT AND REAR BRAKES CHAS EAS00580 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. _ 1. Remove: • brake caliper bolts 1 • brake caliper 2 2. • • • 1 1 Remove: brake pad clips 1 brake pad pin 2 brake pad spring 3 2 3 3. Remove: • brake pads 1 (along with the brake pad shims) • brake pad shims 1 4.
FRONT AND REAR BRAKES 1 2 CHAS 5. Install: • brake pad shims (onto the brake pads) • brake pads • brake pad spring NOTE: Always install new brake pads and a new brake pad spring as a set. _ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. T. Bleed screw 6 Nm (0.
FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER Order 1 2 3 4 5 6 7 8 9 10 Job/Part Q’ty Remarks Removing the rear brake master cylRemove the parts in the order listed. inder Brake fluid Drain. Brake fluid reservoir cover 1 Brake fluid reservoir cap 1 Brake fluid reservoir diaphragm holder 1 Brake fluid reservoir diaphragm 1 Brake fluid reservoir 1 Brake fluid reservoir hose 1 Union bolt 1 Copper washer 2 Brake hose 1 Disconnect. Rear brake light switch 1 Disconnect.
FRONT AND REAR BRAKES Order 11 12 13 14 Job/Part Left footrest assembly Cotter pin Pin Brake master cylinder Q’ty 1 1 1 1 CHAS Remarks For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS 1 5 T. R. 40 Nm (4.0 m • kg, 29 ft • Ib) 5 4 6 2 3 New T. R. Order 1 2 3 4 5 6 Job/Part Removing the front brake calipers Brake fluid Reflector Union bolt Copper washer Brake hose Brake caliper bolt Brake caliper Q’ty 1 1 2 1 2 1 – 40 – 30 Nm (3.0 m • kg, 22 ft • Ib) Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Drain. Refer to “DISASSEMBLING THE FRONT Disconnect.
FRONT AND REAR BRAKES CHAS EAS00615 T. 7 New R. 6 Nm (0.6 m • kg, 4.3 ft • Ib) 8 6 New 7 New 7 6 2 New 7 1 5 3 4 4 5 Order 1 2 3 4 5 6 7 8 Job/Part Disassembling the front brake calipers Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Brake caliper piston Brake caliper piston seal Bleed screw Q’ty 2 1 1 2 2 4 8 1 Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
FRONT AND REAR BRAKES CHAS EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. _ 1. • • • Remove: union bolt 1 copper washers 2 brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. _ 2. Remove: • brake caliper pistons 1 • brake caliper piston seals 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT AND REAR BRAKES CHAS EAS00633 CHECKING THE FRONT BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disassembled 1. Check: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper pistons. • brake caliper cylinders 2 Scratches/wear → Replace the brake caliper assembly.
FRONT AND REAR BRAKES CHAS EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING _ • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 T. 1.
FRONT AND REAR BRAKES CHAS 4. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING _ • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS 7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. (Manual No.
HANDLEBAR CHAS EAS00664 HANDLEBAR Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the handlebar Rear view mirror (left and right) Plastic clamp Front brake light switch connector Brake master cylinder holder Brake master cylinder Right handlebar switch Throttle cable holder Throttle cable Grip end Throttle grip Clutch switch coupler Q’ty 2 4 2 1 1 1 1 2 2 1 1 – 47 – Remarks Remove the parts in the order listed. Disconnect. Disconnect. Disconnect.
HANDLEBAR Order 12 13 14 15 16 17 18 19 Job/Part Left handlebar switch Handlebar grip Clutch cable Clutch lever holder Cable guide Upper handlebar holder Handlebar Lower handlebar holder CHAS Q’ty Remarks 1 1 1 Disconnect. 1 1 1 1 1 For installation, reverse the removal procedure.
REAR SHOCK ABSORBER AND SWINGARM CHAS REAR SHOCK ABSORBER AND SWINGARM Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the rear shock absorber and swingarm Rear wheel Q’ty Adjusting bolt Locknut Mud guard Lower drive belt cover Horn coupler Horn Self-locking nut Bolt (shock absorber-connecting armframe) Cover (left and right) Pivot shaft nut/washer 1 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. 2 1/1 – 49 – Disconnect.
REAR SHOCK ABSORBER AND SWINGARM Order 11 12 Job/Part Pivot shaft Rear shock absorber and swingarm assembly Q’ty 1 1 CHAS Remarks For installation, reverse the removal procedure.
REAR SHOCK ABSORBER AND SWINGARM Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the rear shock absorber and swingarm Self-locking nut/washer/bolt Self-locking nut/washer/bolt Connecting arm O-ring Rear shock absorber Spacer/O-ring Self-locking nut/washer/bolt Relay arm Spacer/oil seal/bearing Spacer/bearing Q’ty Remarks Remove the parts in the order listed. 1/1/1 Bolt 1/1/1 Bolt 2 4 1 1/2 1/1/1 Bolt 1 1/2/1 1/2 – 51 – CHAS = 53 mm (2.19 in) = 124 mm (4.88 in) = 77 mm (3.
REAR SHOCK ABSORBER AND SWINGARM Order 11 12 13 14 15 Job/Part Spacer/bearing Swingarm Dust cover Spacer Bearing Q’ty 1/1 1 2 1 2 CHAS Remarks For installation, reverse the removal procedure.
DRIVE BELT AND DRIVE PULLEY CHAS DRIVE BELT AND DRIVE PULLEY Order 1 2 3 4 5 6 7 8 Job/Part Removing the drive belt and drive pulley Rear wheel Rear shock absorber and swingarm assembly Drive pulley cover bracket Drive pulley cover Dowel pin Slider Drive belt Drive pulley nut Lock washer Drive pulley Q’ty Remarks Remove the parts in the order listed. Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEY”. Refer to “REAR SHOCK ABSORBER AND SWINGARM”.
ENG ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENGINE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2 4 3 54 5 4 5 5 4 5 Quick Gasket® 4 5 3 Quick Gasket® 3 4 5 5 3 4 1 7 5 5 6 New 8 8 New 9 9 T. R.
ENG ROCKER ARMS, PUSH RODS AND VALVE LIFTERS T. R. E 10 Nm (1.0 m • kg, 7.2 ft • Ib) E T. R. 10 11 8 9 20 Nm (2.0 m • kg, 14 ft • Ib) 10 11 10 11 8 9 7 10 11 7 E T. R. 24 Nm (2.
ENG ROCKER ARMS, PUSH RODS AND VALVE LIFTERS T. R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) 4 T. E R. 10 Nm (1.0 m • kg, 7.2 ft • Ib) E 2 6 5 2 1 1 E 7 E 3 7 2 3 2 E Order 1 2 3 4 5 6 7 Job/Part Removing the valve lifters Push rod cover O-ring Seal Air filter bracket Rear valve lifter case Front valve lifter case Valve lifter Q’ty 2 4 2 1 1 1 4 – 56 – E Remarks Remove the parts in the order listed. Refer to “REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS” in chapter 5 (Manual No.
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylinders. 1. Install: • rocker arms 1 • rocker arm shafts 2 (onto rocker arm base) NOTE: The thread hole a of the rocker arm shaft must face to the outside. 2. Install: • dowel pins 1 • rocker arm gasket 2 New È 3. Install: • rocker arm base (with rocker arms) • push rods ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Put the rocker arm base on the cylinder head. b. Install the push rods.
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENG c. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern. T. R. Rocker arm base bolt 1, 2 10 Nm (1.0 m · kg, 7.2 ft · lb) Rocker arm base bolt 3 24 Nm (2.4 m · kg, 17 ft · lb) Bolts 1: M6, Bolts 2: M6, Bolts 3: M8, = 40 mm (1.57 in) = 30 mm (1.18 in) = 70 mm (2.76 in) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ INSTALLING THE CYLINDER HEAD COVERS The following procedure applies to both cylinders. 1.
CLUTCH ENG EAS00274 CLUTCH Order Job/Part Removing the clutch Clutch cover Q’ty Generator rotor cover 1 2 3 4 5 6 7 8 9 Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Clutch plate Wire circlip Clutch plate 1 1 1 1 1 8 7 1 1 – 59 – Remarks Remove the parts in the order listed. Refer to “CLUTCH” in chapter 5. (Manual No.: 4WM-28197-E0) Refer to “GENERATOR AND STARTER CLUTCH” in chapter 5. (Manual No.
CLUTCH Order 10 11 12 13 14 15 16 17 18 19 20 21 22 Job/Part Friction plate Clutch damper spring Clutch damper spring seat Clutch boss Thrust washer Clutch housing Circlip Oil pump drive gear Dowel pin Spacer Pickup coil rotor Primary drive gear Straight key Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 ENG Remarks For installation, reverse the removal procedure.
CLUTCH ENG INSTALLING THE CLUTCH BOSS NUT 1. Install: • washer • clutch boss nut 1 T. R. 105 Nm (10.5 m · kg, 75 ft · lb) NOTE: • Install the washer on the main axle with the “OUT” mark facing away from the motorcycle. • Lock the threads on the clutch boss nut by staking them with a drift punch at the point aligned with the groove in the main axle.
GENERATOR AND STARTER CLUTCH ENG EAS00343 GENERATOR AND STARTER CLUTCH Order Job/Part Removing the generator rotor Generator cover Q’ty 1 2 3 4 5 6 7 Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Woodruff key Starter clutch gear 1 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “GENERATOR AND STARTER CLUTCH” in chapter 5. (Manual No.
CRANKSHAFT AND CONNECTING RODS ENG CRANKSHAFT AND CONNECTING RODS EAS00398 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1. Measure: • crankshaft runout Out of specification → Replace the crankshaft. Maximum crankshaft runout 0.04 mm (0.0016 in) 2. • • • Check: crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches/wear → Replace the crankshaft and bearings. • generator shaft drive gear 1 Damage/wear → Replace the crankshaft. 3.
CRANKSHAFT AND CONNECTING RODS ENG b. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap. NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap. c. Put a piece of Plastigauge® 1 on the crankshaft pin. d. Assemble the connecting rod halves. NOTE: • Do not move the connecting rod or crankshaft until the clearance measurement has been completed.
CRANKSHAFT AND CONNECTING RODS ENG WARNING When a bolt is tightened more than the specified angle, do not loosen them and then retighten them. Replace the bolt with a new one and perform the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt until it is at the specified angle. NOTE: The angle between the corners of the connecting rod bolts is 30°. h. Remove the connecting rod and big end bearings.
CRANKSHAFT AND CONNECTING RODS ENG 4. Select: • big end bearings (P1 ~ P2) NOTE: • The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes. • “P1” ~ “P2” refer to the bearings shown in the crankshaft illustration.
CRANKSHAFT AND CONNECTING RODS ENG 6. Measure: • crankshaft journal bearing inside diameter a Out of specification → Replace the crankcase assembly. Crankshaft journal bearing inside diameter 50.01 ~ 50.03 mm (1.969 ~ 1.970 in) NOTE: Measure the inside diameter of each crankshaft journal bearing at two places. 7. Calculate: • crankshaft journal-to-crankshaft journal bearing clearance Out of specification → Replace the crankshaft and crankshaft journal bearings as a set.
CRANKSHAFT AND CONNECTING RODS 2. • • • ENG Lubricate: crankshaft pins big end bearings connecting rod inner surface (with the recommended lubricant) Recommended lubricant Engine oil 3. • • • Install: big end bearings connecting rods connecting rod caps (onto the crankshaft pins) NOTE: • Align the projections a on the big end bearings with the notches b in the connecting rods and connecting rod caps. • Be sure to reinstall each big end bearing in its original place.
CRANKSHAFT AND CONNECTING RODS ENG ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Tighten the connecting rod bolts to the specified torque. T. R. Connecting rod bolts 1st 15 mm (1.5 m · kg, 11 ft · lb) b. Tighten the connecting rod bolts further to reach the specified angle 90° ~ 120°. T. R. Connecting rod bolts Final Specified angle 90° ~ 120° WARNING When a bolt is tightened more than the specified angle, do not loosen it and then retighten it.
TRANSMISSION ENG TRANSMISSION Order 1 2 3 4 5 6 7 8 9 Job/Part Q’ty Remarks Disassembling the main axle assemRemove the parts in the order listed. bly Main axle assembly Refer to “TRANSMISSION” in chapter 5. (Manual No.: 4WM-28197-E0) Circlip 1 Washer 1 5th pinion gear 1 2nd/3rd pinion gear 1 Circlip 1 Washer 1 4th pinion gear 1 Spacer 1 Main axle/1st pinion gear 1 For assembly, reverse the disassembly procedure.
AIR INDUCTION SYSTEM CARB CARBURETOR AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cut-off valve 3 Front cylinder head 4 Rear cylinder head 5 Air cleaner 6 Carburetor joint È To the carburetor joint É To the air cut-off valve 4 3 È 2 A 1 È 5 2 É 6 1 A – 71 –
AIR INDUCTION SYSTEM Order Job/Part Removing the air induction system Fuel tank Fuel pump Q’ty 1 Reed valve case to rear cylinder head hose 1 Reed valve case to rear cylinder head pipe 1 Reed valve case to rear cylinder head hose 2 Reed valve case to rear cylinder head pipe 2 Gasket Reed valve case to front cylinder head hose 1 2 3 4 5 6 1 1 1 2 1 – 72 – CARB Remarks Remove the parts in the order listed. Refer to “FUEL TANK” Refer to “CARBURETOR” in chapter 6. (Manual No.
AIR INDUCTION SYSTEM Order 7 8 9 10 11 12 13 14 15 16 17 18 19 Job/Part Reed valve case to front cylinder head pipe Rectifier/regulator coupler Rectifier/regulator Air filter bracket Air filter Air filter cover Air filter hose Air cut-off valve to air filter hose Plastic locking tie Vacuum hose Bracket Air cut-off valve holder Air cut-off valve Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 – 73 – CARB Remarks Disconnect.
AIR INDUCTION SYSTEM Order 20 21 22 23 24 25 Job/Part Air cut-off valve to reed valve cover hose Reed valve cover Reed valve case Reed valve base Reed valve stopper Reed valve Q’ty 1 CARB Remarks 1 1 1 2 2 For installation, reverse the removal procedure.
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
XV17AS(C)/XV17ASS(C)/XV17ATS(C) WIRING DIAGRAM W W W 1 W W W W W W R R 2 8 R/G B B R W W W L 5 R R R R Sb/W R/B B Br/L R L/B L/Y (BLACK) (BLACK) R/W Gy2 B Y/B O R/B L/W B/Y R/W Sb L/Y Gy2 L/R L/B L/G B B B 0 7 B Br/L L/B L/Y B L/B L/B B (BLACK) (BLACK) B L/G B (BLUE) (BLUE) Ch Dg B L Y WIRE HARNESS SUB-WIRE HARNESS G/R B B Dg Ch Y L B D Gy2 B L/R L/B A B A L/G B R Br/L L/Y L/B C Sb/W R/B L L/B L/R L/G L/Y Sb B/Y L/W 9 R R R/W L L 6 4 3 D Gy L
