Content .. 2 3 4 5 ..

Yamaha XV1700P, XV1700PC. Service Manual - part 4

1 - 33

GEN

INFO

IMPORTANT INFORMATION

EAS00023

LOCK WASHERS/PLATES AND COTTER
PINS

After removal, replace all lock washers/plates

and cotter pins. After the bolt or nut has

been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.

EAS00024

BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro-
priate.

Oil seal

CAUTION:

Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.

Bearing

EAS00025

CIRCLIPS

Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip

, make sure the

sharp-edged corner

is positioned opposite

the thrust

that the circlip receives.

Shaft

1 - 34

GEN

INFO

CHECKING THE CONNECTIONS

EAS00026

CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:

• lead
• coupler
• connector

2. Check:

• lead
• coupler
• connector

Moisture

→

Dry with an air blower.

Rust/stains

→

Connect and disconnect sev-

eral times.

3. Check:

• all connections

Loose connection

→

Connect properly.

NOTE:

If the pin

on the terminal is flattened, bend it

up.

4. Connect:

• lead
• coupler
• connector

NOTE:

Make sure all connections are tight.

5. Check:

• continuity (with the pocket tester)

NOTE:

• If there is no continuity, clean the terminals.
• When checking the wire harness, perform

steps (1) to (3).

• As a quick remedy, use a contact revitalizer

available at most part stores.

Pocket tester

YU-03112

1 - 35

GEN

INFO

SPECIAL TOOLS

EAS00027

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.

Tool No.

Tool name/Function

Illustration

YB-35956

Mity vac

This tool used to measure the vacuum
pressure.

YM-01080-A

Alternator rotor puller

This tool is used to remove the genera-
tor rotor.

YM-01423

Damper rod holder

This tool is used to hold the damper rod
assembly when loosening or tightening
the damper rod assembly bolt.

YM-01434

Rod holder

This tool is used to support the damper
adjusting rod.

Rod puller
YM-01437

Rod puller

These tools are used to pull up the front
fork damper rod.

YM-01441

Fork spring compressor

This tool is used to disassemble or
assemble the front fork legs.

YM-01442

Fork seal driver

This tool is used to install the front fork’s
oil seal and dust seal.

1 - 36

GEN

INFO

SPECIAL TOOLS

YM-04019

Valve spring compressor set

This tool is used to remove or install the
valve assemblies.

YM-04058

Bearing driver

This tool is needed when installing the
crankshaft journal bearing.

YM-04064-A

Valve guide remover (ø6)

This tool is used to remove or install the
valve guides.

YM-04065-A

Valve guide installer (ø6)

This tool is used to install the valve
guides.

YM-04066

Valve guide reamer (ø6)

This tool is used to rebore the new
valve guides.

YM-28898

Bearing remover and installer

This tool is needed when removing or
installing the crankshaft journal bearing.

YM-33277-A

Timing light

This tool is used to check the ignition
timing.

YM-03170

Belt tension gauge

This tool is used to measure the drive
belt slack.

Tool No.

Tool name/Function

Illustration

1 - 37

GEN

INFO

SPECIAL TOOLS

YM-34487

Dynamic spark tester

This tool is used to check the ignition
system components.

YM-8035

Valve adjuster

This tool is used to adjust the valve
clearance.

YM-91042

Universal clutch holder

This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.

YS-01880-A

Primary sheave holder

This tool is used to hold the generator
rotor when removing or installing the
generator rotor bolt, generator shaft bolt
or crankshaft position sensor rotor bolt.

YU-01304

Piston pin puller

This tool is used to remove the piston
pins.

YU-03009

Micrometer (75 ~ 100 mm)

This tool is used to measure the piston
skirt diameter.

YU-03017

Cylinder bore gauge (50 ~ 100 mm)

This tool is used to measure the cylin-
der bore.

YU-03112

Pocket tester

This tool is used to check the electrical
system.

Tool No.

Tool name/Function

Illustration

1 - 38

GEN

INFO

SPECIAL TOOLS

YU-08030

Carburetor synchronizer

This gauge is needed for throttle bodies
synchronization.

Compression gauge

YU-33223

Compression gauge

adapter

YU-33223-3

Compression gauge set 14/18 mm
Compression gauge adapter 12 mm

These tools are used to measure
engine compression.

YU-33975

Spanner wrench

This tool is used to loosen or tighten the
steering stem ring nuts.

YU-38411

Oil filter wrench

This tool is needed to loosen or tighten
the oil filter cartridge.

YU-8036-A

Inductive tachometer

This tool is used for check engine
speed.

ACC-11001-05-01

Quick Gasket

This sealant is used to seal two mating
surfaces (e. g., crankcase mating sur-
faces).

Gauge

YU-03153

Oil pressure adaptor E

YM-03129

Pressure gauge
Oil pressure adaptor E

These tools are needed to measure
engine oil pressure.

YM-03176

Fuel pressure adapter

This tool is needed to measure fuel
pressure.

Tool No.

Tool name/Function

Illustration

1 - 39

GEN

INFO

SPECIAL TOOLS

YM-01485

Pivot shaft wrench

This tool is needed to loosen or tighten
the spacer bolt.

Tool No.

Tool name/Function

Illustration

2 - 1

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item

Standard

Limit

Model code

5PX1 (USA)
5PX2 (California)
5PX3 (CDN)

----
----
----

Dimensions

Overall length

2,385 mm (93.9 in)

----

Overall width

955 mm (37.6 in)

----

Overall height

1,120 mm (44.1 in)

----

Seat height

725 mm (28.5 in)

----

Wheelbase

1,665 mm (65.6 in)

----

Minimum ground clearance

155 mm (6.10 in)

----

Minimum turning radius

3,400 mm (133.9 in)

----

Weight

Wet (with oil and a full fuel tank)

295 kg (650 lb)

----

Dry (without oil and fuel)

278 kg (613 lb)

----

Gross vehicle weight ratio (GVWR)

480 kg (1,058 lb)

----

Bias weight (dry) front

133 kg (293 lb)

----

Bias weight (dry) rear

145 kg (320 lb)

----

Maximum load (total of cargo, rider,
passenger, and accessories)

185 kg (408 lb)

----

2 - 2

SPEC

ENGINE SPECIFICATIONS

Item

Standard

Limit

Engine

Engine type

Air-cooled, 4-stroke, OHV

----

Displacement

1,670 cm

(101.9 cu.in)

----

Cylinder arrangement

V-type 2-cylinder

----

Bore

stroke

113 mm (3.82

4.45 in)

----

Compression ratio

8.36 : 1

----

Engine idling speed

850 ~ 950 r/min

----

CO%

4.0 ~ 5.0 %

----

Vacuum pressure at engine idling
speed

50 kPa (375 mm Hg, 14.8 in Hg)

----

Standard compression pressure
(at sea level)

1,200 kPa
(12.0 kg/cm

, 171 psi) at 200 r/min

----

Minimum compression pressure

1,000 kPa (10.0 kg/cm

, 145 psi)

----

Maximum compression pressure

1,400 kPa (14.0 kg/cm

, 203 psi)

----

Engine dry weight

108 kg (238 lb)

----

Fuel

Recommended fuel

Unleaded fuel only (USA and California)
Regular unleaded gasoline only (CDN)

----
----

Fuel tank capacity

Total (including reserve)

15 L (13.2 Imp qt, 15.86 US qt)

----

Reserve only

3 L (2.64 Imp qt, 3.17 US qt)

----

Engine oil

Lubrication system

Dry sump

----

Recommended oil

Yamalube 4 (20W40) or SAE 20W40 type
SE motor oil (40 °F/5 °C or above)
(Non-Friction modified)

----

Quantity

Total amount

5.0 L (4.40 Imp qt, 5.29 US qt)

----

Engine

2.0 L (1.76 Imp qt, 2.11 US qt)

----

Oil tank

3.0 L (2.64 Imp qt, 3.17 US qt)

----

Without oil filter cartridge replace-
ment

3.7 L (3.26 Imp qt, 3.91 US qt)

----

With oil filter cartridge replacement

4.1 L (3.61 Imp qt, 4.33 US qt)

----

Oil pressure (hot)

60 kPa (0.6 kg/cm

, 8.5 psi) at 900 r/min

----

Relief valve opening pressure

600 kPa (6.0 kg/cm

, 85 psi)

----

Oil temperature

70 ~ 90 °C (158 ~ 194 °F)

----

2 - 3

SPEC

ENGINE SPECIFICATIONS

Transfer gear oil

Recommended oil

SAE 80 API “GL-4” hypoid gear oil

----

Total amount

0.49 L (0.43 Imp qt, 0.52 US qt)

----

Periodic oil replacement

0.4 L (0.35 Imp qt, 0.42 US qt)

----

Oil filter

Oil filter type

Cartridge (paper)

----

Bypass valve opening pressure

80 ~ 120 kPa
(0.8 ~ 1.2 kg/cm

, 11.3 ~ 17.1 psi)

----

Engine oil pump

Oil pump type

Trochoid

----

Inner rotor to outer rotor tip clearance 0 ~ 0.12 mm (0 ~ 0.0047 in)

0.17 mm
(0.0067 in)

Outer rotor to oil pump housing
clearance (feed pump)

0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)

0.13 mm
(0.0051 in)

Outer rotor to oil pump housing
clearance (scavenging pump)

0.06 ~ 0.11 mm (0.0024 ~ 0.0043 in)

0.16 mm
(0.0063 in)

Transfer oil pump

Oil pump type

Trochoid

----

Inner rotor to outer rotor tip clearance 0.07 ~ 0.12 mm (0.0028 ~ 0.0047 in)

0.17 mm
(0.0067 in)

Outer rotor to oil pump housing clear-
ance

0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)

0.16 mm
(0.0063 in)

Bypass valve opening pressure

80 ~ 120 kPa
(0.8 ~ 1.2 kg/cm

, 11.3 ~ 17.1 psi)

----

Relief valve opening pressure

600 kPa (6.0 kg/cm

, 85 psi)

----

Oil pressure (hot)

60 kPa (0.6 kg/cm

, 8.5 psi) at 900 r/min

----

Starting system type

Electric starter

----

Electric fuel injection

Model

IMP-732

----

Manufacturer

NIPPON INJECTOR

----

Quantity

----

Spark plugs

Model DPR7EA-9/X22EPR-U9

----

Manufacturer

NGK/DENSO

----

Quantity

----

Spark plug gap

0.8 ~ 0.9 mm (0.0315 ~ 0.0354 in)

----

Cylinder heads

Volume

98.6 ~ 103.6 cm

(6.02 ~ 6.32 cu.in)

----

Max. warpage

----

0.03 mm
(0.0012 in)

Item

Standard

Limit

2 - 4

SPEC

ENGINE SPECIFICATIONS

Camshafts

Drive system

Gear drive

----

Crankcase hole inside diameter

25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in)

----

Camshaft cover hole inside diameter

28.000 ~ 28.021 mm (1.1024 ~ 1.1032 in)

----

Camshaft journal diameter
(crankcase side)

24.937 ~ 24.950 mm (0.9818 ~ 0.9823 in)

----

Camshaft journal diameter
(camshaft cover side)

27.967 ~ 27.980 mm (1.1011 ~ 1.1016 in)

----

Camshaft to crankcase clearance

0.050 ~ 0.084 mm (0.0020 ~ 0.0033 in)

----

Camshaft to camshaft cover clear-
ance

0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in)

----

Camshaft intake cam dimensions

Measurement A

38.231 ~ 38.331 mm (1.5052 ~ 1.5091 in) 38.131 mm

(1.5012 in)

Measurement B

32.013 ~ 32.113 mm (1.2604 ~ 1.2643 in) 31.913 mm

(1.2564 in)

Camshaft exhaust cam dimensions

Measurement A

38.232 ~ 38.332 mm (1.5052 ~ 1.5091 in) 38.132 mm

(1.5013 in)

Measurement B

31.995 ~ 32.095 mm (1.2596 ~ 1.2636 in) 31.895 mm

(1.2557 in)

Item

Standard

Limit

2 - 5

SPEC

ENGINE SPECIFICATIONS

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) 14.970 mm

(0.5894 in)

Rocker arm to rocker arm shaft clear-
ance

0.009 ~ 0.042 mm (0.0004 ~ 0.0017 in)

0.08 mm
(0.003 in)

Lift ratio (Y/X)

40.4/29.5 = 1.37

----

Valves, valve seats, valve guides

Valve clearance (cold)

----

Intake

0 ~ 0.04 mm (0 ~ 0.0016 in)

----

Exhaust

0 ~ 0.04 mm (0 ~ 0.0016 in)

----

Valve dimensions

Valve head diameter A

Intake

33.9 ~ 34.1 mm (1.3346 ~ 1.3425 in)

----

Exhaust

27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in)

----

Valve face width B

Intake

1.3 ~ 2.3 mm (0.0512 ~ 0.0906 in)

----

Exhaust

1.2 ~ 2.4 mm (0.0472 ~ 0.0945 in)

----

Valve seat width C

Intake

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

2.0 mm
(0.079 in)

Exhaust

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)

2.0 mm
(0.079 in)

Valve margin thickness D

Intake

0.7 ~ 1.3 mm (0.0276 ~ 0.0512 in)

0.4 mm
(0.016 in)

Exhaust

0.7 ~ 1.3 mm (0.0276 ~ 0.0512 in)

0.4 mm
(0.016 in)

Item

Standard

Limit

Head Diameter

Face Width

Seat Width

Margin Thickness

2 - 6

SPEC

ENGINE SPECIFICATIONS

Valve stem diameter

Intake

5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in)

5.945 mm
(0.2341 in)

Exhaust

5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in)

5.920 mm
(0.2331 in)

Valve guide inside diameter

Intake

6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)

6.05 mm
(0.2382 in)

Exhaust

6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in)

6.05 mm
(0.2382 in)

Valve stem-to-valve guide clear-
ance

Intake

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)

0.08 mm
(0.0031 in)

Exhaust

0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in)

0.1 mm
(0.0039 in)

Valve stem runout

----

0.01 mm
(0.0004 in)

Valve seat material

Intake

PB 6

----

Exhaust

V557W

----

Valve springs

Inner springs

Free length

Intake

38.26 mm (1.51 in)

36.26 mm
(1.43 in)

Exhaust

38.26 mm (1.51 in)

36.26 mm
(1.43 in)

Spring rate-intake (K1)

7.3 N/mm (41.68 lb/in)

----

Spring rate-intake (K2)

8.8 N/mm (50.25 lb/in)

----

Spring rate-exhaust (K1)

7.3 N/mm (41.68 lb/in)

----

Spring rate-exhaust (K2)

8.8 N/mm (50.25 lb/in)

----

Installed length (valve closed)

Intake

29.0 mm (1.14 in)

----

Exhaust

29.0 mm (1.14 in)

----

Item

Standard

Limit

2 - 7

SPEC

ENGINE SPECIFICATIONS

Compressed spring force
(installed)

Intake

63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb)

----

Exhaust

63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb)

----

Spring tilt

Intake

----

2.5°/2.4 mm
(2.5°/0.094 in)

Exhaust

----

2.5°/2.4 mm
(2.5°/0.094 in)

Winding direction (top view)

Intake

Counterclockwise

----

Exhaust

Counterclockwise

----

Outer springs

Free length

Intake

43.25 mm (1.70 in)

41.26 mm
(1.62 in)

Exhaust

43.25 mm (1.70 in)

41.26 mm
(1.62 in)

Spring rate-intake (K1)

12.2 N/mm (69.66 lb/in)

----

Spring rate-intake (K2)

14.9 N/mm (85.08 lb/in)

----

Spring rate-exhaust (K1)

12.2 N/mm (69.66 lb/in)

----

Spring rate-exhaust (K2)

14.9 N/mm (85.08 lb/in)

----

Installed length (valve closed)

Intake

31.0 mm (1.22 in)

----

Exhaust

31.0 mm (1.22 in)

----

Compressed spring force
(installed)

Intake

139 ~ 161 N
(13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)

----

Exhaust

139 ~ 161 N
(13.9 ~ 16.1 kg, 30.6 ~ 35.5 lb)

----

Item

Standard

Limit

2 - 8

SPEC

ENGINE SPECIFICATIONS

Spring tilt

Intake

----

2.5°/2.4 mm
(2.5°/0.094 in)

Exhaust

----

2.5°/2.4 mm
(2.5°/0.094 in)

Winding direction (top view)

Intake

Clockwise

----

Exhaust

Clockwise

----

Valve lifters

Valve lifter outside diameter

22.9680 ~ 22.9744 mm
(0.9043 ~ 0.9045 in)

----

Valve lifter case inside diameter

23.000 ~ 23.021 mm (0.9055 ~ 0.9063 in)

----

Valve lifter-to-valve lifter case clear-
ance

0.0256 ~ 0.0530 mm (0.0010 ~ 0.0021 in)

----

Valve push rods

Valve push rod 1 length

288.5 mm (11.358 in)

----

Valve push rod 2 length

290.5 mm (11.437 in)

----

Valve push rod runout

0.3 mm (0.012 in)

----

Cylinders

Material

Aluminum alloy

----

Sleeve type

Ceramic composite plated

----

Bore

97.000 ~ 97.010 mm (3.8189 ~ 3.8193 in)

----

Max. taper

----

0.05 mm
(0.00197 in)

Max. out of round

----

0.05 mm
(0.00197 in)

Item

Standard

Limit

2 - 9

SPEC

ENGINE SPECIFICATIONS

Pistons

Piston-to-cylinder clearance

0.025 ~ 0.050 mm (0.001 ~ 0.002 in)

0.15 mm
(0.006 in)

Diameter D

96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in)

----

Height H

5 mm (0.20 in)

----

Piston pin bore (in the piston)

Diameter

22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm

(0.8679 in)

Offset

1.0 mm (0.0394 in)

----

Piston pins

Outside diameter

21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in) 21.971 mm

(0.8650 in)

Piston pin-to-piston pin bore clear-
ance

0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) 0.074 mm

(0.0029 in)

Piston rings

Top ring

Ring type

Barrel

----

Dimensions (B

1.2

3.8 mm (0.047

0.150 in)

----

End gap (installed)

0.30 ~ 0.45 mm (0.012 ~ 0.018 in)

0.65 mm
(0.026 in)

Ring side clearance

0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in)

0.12 mm
(0.0047 in)

Plating/coating

Chrome plated/parkerizing

----

Item

Standard

Limit

Content .. 2 3 4 5 ..