Yamaha XV1700PCRC Road Star Warrior Manual de usuario

LIT-11616-16-36 5PX-28197-11

XV1700PCR

XV1700PCRC

SUPPLEMENTARY

SERVICE MANUAL

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

XV1700PCR/XV1700PCRC. For complete service information procedures it is necessary to use this

Supplementary Service Manual together with the following manual.

XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10)

XV1700PCR/XV1700PCRC

SUPPLEMENTARY

SERVICE MANUAL

First Edition, July 2002

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-16-36

EAS00003

NOTICE

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.

NOTE:

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to

the motorcycle operator, a bystander or a person checking or repairing the

motorcycle.

A CAUTION indicates special precautions that must be taken to avoid damage

to the motorcycle.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

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.

1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of

each page indicate the current chapter.

Refer to “SYMBOLS”.

2Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section

title(s) appears.

3Sub-section titles appear in smaller print than the section title.

4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of

each removal and disassembly section.

5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

6Symbols indicate parts to be lubricated or replaced.

Refer to “SYMBOLS”.

7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of

parts, notes in jobs, etc.

8Jobs requiring more information (such as special tools and technical data) are described sequen-

tially.

EAS00009

SYMBOLS

The following symbols are not relevant to

every vehicle. Symbols 1to 8indicate the

subject of each chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Fuel injection system

7Electrical system

8Troubleshooting

Symbols 9to Findicate the following.

9Serviceable with engine mounted

0Filling fluid

ALubricant

BSpecial tool

CTightening torque

DWear limit, clearance

EEngine speed

FElectrical data

Symbols Gto Lin the exploded diagrams

indicate the types of lubricants and lubrication

points.

GEngine oil

HGear oil

IMolybdenum-disulfide oil

JWheel-bearing grease

KLithium-soap-based grease

LMolybdenum-disulfide grease

Symbols Mto Nin the exploded diagrams

indicate the following.

MApply locking agent (LOCTITE®)

NReplace the part

GHI

JKL

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG FI

–+

ELEC TRBL

SHTG

EGM

BLS M

New

CONTENTS

SPECIFICATIONS ........................................................................................... 1

GENERAL SPECIFICATIONS ................................................................. 1

ENGINE SPECIFICATIONS .................................................................... 1

CHASSIS SPECIFICATIONS ................................................................... 1

ELECTRICAL SPECIFICATIONS ............................................................ 2

TIGHTENING TORQUES ......................................................................... 2

CHASSIS TIGHTENING TORQUES .................................................... 2

CABLE ROUTING .................................................................................... 3

PERIODIC CHECKS AND ADJUSTMENTS ................................................. 11

INTRODUCTION .................................................................................... 11

PERIODIC MAINTENANCE CHART FOR

THE EMISSION CONTROL SYSTEM ................................................ 11

GENERAL MAINTENANCE AND LUBRICATION CHART .................... 12

CHASSIS ................................................................................................ 14

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ............. 14

CHASSIS ....................................................................................................... 16

FRONT AND REAR BRAKES ................................................................ 16

REAR BRAKE MASTER CYLINDER ................................................. 16

REAR SHOCK ABSORBER AND SWINGARM ..................................... 18

ENGINE .......................................................................................................... 22

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ....................... 22

GENERATOR AND STARTER CLUTCH ............................................... 24

STATOR COIL ASSEMBLY ............................................................... 24

– 1 –

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

Item Standard Limit

Model code 5PX4 (USA)

5PX5 (California)

5PX6 (CDN)

----

Item Standard Limit

Electronic fuel injection

Model (manufacturer) INP-732 (NIPPON INJECTOR) ----

Quantity 2 ----

Crankshaft

Width A 132.8 ~ 133.2 mm (5.228 ~ 5.244 in) ----

Max. runout C ---- 0.04 mm

(0.0016 in)

Big end side clearance D 0.320 ~ 0.474 mm (0.0126 ~ 0.0187 in) ----

Big end radial clearance E 0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) 0.09 mm

(0.0035 in)

Crankshaft journal-to-crankshaft-

journal bearing clearance

0.032 ~ 0.062 mm (0.0012 ~ 0.0024 in) 0.1 mm

(0.0039 in)

Fuel pump

Pump type Electrical ----

Model (manufacturer) 5PX (MITSUBISHI) ----

Max. consumption amperage 5 A ----

Output pressure 392 ~ 588 kPa

(3.92 ~ 5.88 kg/cm2, 55.7 ~ 83.6 psi)

----

Item Standard Limit

Front tire

Tire type Tubeless ----

Size 120/70 ZR 18 M/C (59 W)

120/70 ZR 18 (59 W)

----

Model (manufacturer) D220F ST G (DUNLOP)/

BT020F G (BRIDGESTONE)

----

GENERAL SPECIFICATIONS/

ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS

–2 –

SPEC

ELECTRICAL SPECIFICATIONS

TIGHTENING TORQUES

CHASSIS TIGHTENING TORQUES

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm2, 36 psi) ----

90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kgf/cm2, 36 psi) ----

High-speed riding 250 kPa (2.5 kgf/cm2, 36 psi) ----

* Load is the total weight of the cargo,

rider, passenger and accessories.

Min. tire tread depth ---- 1.0 mm

(0.04 in)

Rear tire

Tire type Tubeless ----

Size 200/50 ZR 17 M/C (75 W)

200/50 ZR 17 (75 W)

----

Model (manufacturer) D220 ST (DUNLOP)/

BT020R (BRIDGESTONE)

----

Tire pressure (cold)

0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm2, 36 psi) ----

90 kg (198 lb) ~ Maximum load* 290 kPa (2.9 kgf/cm2, 42 psi) ----

High-speed riding 250 kPa (2.5 kgf/cm2, 36 psi) ----

* Load is the total weight of the cargo,

rider, passenger and accessories.

Min. tire tread depth ---- 1.0 mm

(0.04 in)

Item Standard Limit

Ignition coils

Model (manufacturer) J0447 (DENSO) ----

Minimum ignition spark gap 6 mm (0.24 in) ----

Primary coil resistance 1.32 ~ 1.78 Ω----

Secondary coil resistance 12 ~ 18 kΩ----

Charging system

System type AC magneto ----

Model (manufacturer) F5PX (YAMAHA) ----

Nominal output 14 V/31 A at 5,000 r/min ----

Stator coil resistance/color 0.13 ~ 0.19 Ω/W–W ----

Item Thread size Tightening torque Remarks

Nm m·kg ft·lb

Rider footrest bracket and frame M10 48 4.8 35 LT

Rear fender and turn signal light bracket (upper) M6 7 0.7 5.1

Rear fender and turn signal light bracket (lower) M6 9 0.9 6.5

Canister and rider footrest bracket (For California

only)

M6 9 0.9 6.5

Item Standard Limit

CHASSIS SPECIFICATIONS/

ELECTRICAL SPECIFICATIONS/TIGHTENING TORQUES

–3 –

SPEC

EB206000

CABLE ROUTING

1Brake hose

2Clutch cable

3Rectifier/regulator

4Rectifier/regulator lead

5Rear brake light switch lead

6Horn lead

7Stator coil assembly lead

ÈFasten the rectifier/regulator

lead, horn lead, and rear brake

light switch lead with a plastic

locking tie to the frame.

ÉFasten the stator coil assem-

bly lead and rectifier/regulator

lead with a plastic clamp.

ÊFasten the rear brake light

switch lead, horn lead, and

stator coil assembly lead with

a plastic locking tie to the

frame.

ËFasten the stator coil assem-

bly lead, horn lead, and rear

brake light switch lead with a

plastic locking tie to the frame.

CABLE ROUTING

–4 –

SPEC

1Tachometer couplers

2Right handlebar switch coupler and speedome-

ter couplers

3Main switch coupler

4Left handlebar switch couplers

5Left and right turn signal/position light connec-

tors

ÈSecure the wire harness in the holder at the

white tape on the harness.

ÉRoute each lead behind the headlight assembly

bracket bolts.

ÉÉ

CABLE ROUTING

Este manual sirve para los siguientes modelos

Tabla de contenidos

Otros manuales de Motocicleta de Yamaha

Yamaha

Yamaha FZ750 1987 Manual de usuario

Yamaha

Yamaha T115SE 2019 Manual de usuario

Yamaha

Yamaha FZ6-SA Manual de usuario

Yamaha

Yamaha NEO'S YN50 Manual de usuario

Yamaha

Yamaha Super Tenere XTZ1200Z Manual de usuario

Yamaha

Yamaha FZS1000 2003 Manual

Yamaha

Yamaha VMAX VMX17 Manual de usuario

Yamaha

Yamaha YZ250F(E) Guía de aplicación

Yamaha

Yamaha GT 125 2017 Manual de usuario

Yamaha

Yamaha TRACER 700 2020 Manual de usuario

Yamaha

Yamaha YZ125 2022 Guía de aplicación

Yamaha

Yamaha Tmax XP500Z Manual de usuario

Yamaha

Yamaha YZ450FA 2011 Guía de aplicación

Yamaha

Yamaha DragStar XVS1100 Manual de usuario

Yamaha

Yamaha VMAX 2009 Manual de usuario

Yamaha

Yamaha midnightstar XV1900A Manual de usuario

Yamaha

Yamaha WR250F 2022 Guía de aplicación

Yamaha

Yamaha MT-09 SP Manual de usuario

Yamaha

Yamaha YZF660N 2022 Manual de usuario

Yamaha

Yamaha WR450F(T) Guía de aplicación

Yamaha

Yamaha Vmax VMX17C 2009 Manual de usuario

Yamaha

Yamaha PW80(T) Guía de aplicación

Yamaha

Yamaha PW80(A) Manual de usuario

Yamaha

Yamaha FJR1300A Manual de usuario

Manuales populares de Motocicleta de otras marcas

OHVALE

OHVALE GP-0 Manual de lista de piezas

KTM

KTM 350 XCF-W USA Manual de usuario

HYOSUNG

HYOSUNG ST7 Manual de usuario

Husqvarna

Husqvarna FC 250 2016 Manual de usuario

Ducati

Ducati SCRAMBLER 800 Manual de instrucciones

MOTO GUZZI

MOTO GUZZI QUOTA 1100 ES Manual de usuario

APRILIA

APRILIA ETV MILLE CAPONORD - PART1 02-2001 Manual de usuario

KTM

KTM Freeride E-XC 2021 Manual de usuario

Fantic

Fantic Enduro 125 Manual de usuario

Ducati

Ducati Supersport 750 desmodue Manual de usuario

MV Agusta

MV Agusta 2008 F4 312RR 1078 Manual de instrucciones

Ducati

Ducati 748 monoposto strada Manual de usuario

ATK

ATK 1988 250 Manual de usuario

Excelsior-HENDERSON

Excelsior-HENDERSON 1999 HCX Manual de usuario

Triumph

Triumph Thunderbird Manual de usuario

Ducati

Ducati 996 Manual de usuario

BMW

BMW MOTORRAD K 1200 R Sport Manual de instalación y mantenimiento

BMW Motorrad

BMW Motorrad G 650 GS 2007 Manual de instalación y mantenimiento