Yamaha XV1700P, XV1700PC. Service Manual - part 13

4 - 17

CHAS

REAR WHEEL, BRAKE DISC, AND REAR WHEEL

PULLEY

EAS00561

REMOVING THE REAR WHEEL

1. Stand the motorcycle on a level surface.

WARNING

_ 

Securely support the motorcycle so that
there is no danger of it falling over. 

NOTE:

_ 

Place the motorcycle on a suitable stand so
that the rear wheel is elevated. 

2. Remove: 

• brake caliper

NOTE:

_ 

Do not depress the brake pedal when remov-
ing the brake caliper. 

3. Loosen: 

• locknuts 
• adjusting nuts 

4. Remove: 

• wheel axle nut 
• wheel axle 
• rear wheel

NOTE:

_ 

Push the rear wheel forward and remove the
drive belt from the rear wheel pulley. 

EAS00565

CHECKING THE REAR WHEEL

1. Check: 

• wheel axle 
• rear wheel 
• wheel bearings 
• oil seals 

Refer to “CHECKING THE FRONT
WHEEL”.

2. Check: 

• tire 
• rear wheel 

Damage/wear 

→

 Replace. 

Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.

3. Measure: 

• radial wheel runout 
• lateral wheel runout 

Refer to “FRONT WHEEL AND BRAKE
DISCS”.

4 - 18

CHAS

REAR WHEEL, BRAKE DISC, AND REAR WHEEL

PULLEY

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB

1. Check: 

• rear wheel drive hub 

1

Cracks/damage 

→

 Replace. 

• rear wheel drive hub dampers 

2

Damage/wear 

→

 Replace.

EAS00568

CHECKING AND REPLACING THE REAR 
WHEEL PULLEY

1. Check: 

• rear wheel pulley 

Surface plating has come 

→

 Replace the

rear wheel pulley. 
Bent teeth 

→

 Replace the rear wheel pul-

ley.

2. Replace: 

• rear wheel pulley

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a. Remove the self-locking nuts and the rear

wheel pulley. 

b. Clean the rear wheel drive hub with a clean

cloth, especially the surfaces that contact
the pulley. 

c. Install the new rear wheel pulley.

NOTE:

_ 

Tighten the self-locking nuts in stages and in a
crisscross pattern. 

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Rear wheel pulley self-locking nut 

95 Nm (9.5 m • kg, 68 ft • lb)

ASSEMBLING THE REAR WHEEL

1. Install: 

• bearings
• spacer
• bearing
• oil seal

 

Refer to “FRONT WHEEL AND BRAKE
DISCS”.

New

4 - 19

CHAS

REAR WHEEL, BRAKE DISC, AND REAR WHEEL

PULLEY

EAS00572

INSTALLING THE REAR WHEEL

1. Lubricate: 

• oil seal lips

Recommended lubricant 

Lithium-soap-based grease

2. Install: 

• rear wheel drive hub dampers 

1

 

3. Install: 

• rear wheel drive hub assembly 

1

 

4. Install: 

• rear wheel pulley 

1

 

NOTE:

Tighten the self-locking nuts in stages and in a
crisscross pattern.
Install the rear wheel pulley with its wider
spokes situated on top of the rear wheel
spokes.

5. Install: 

• brake disc 
• brake disc cover

NOTE:

• Apply locking agent (LOCTITE

®

 648) to the

threads of the brake disc bolts.

• Tighten the brake disc bolts in stages and in

a crisscross pattern.

T

 

R

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95 Nm (9.5 m  •  kg, 68 ft  •  lb)

4 - 20

CHAS

REAR WHEEL, BRAKE DISC, AND REAR WHEEL

PULLEY

6. Install: 

• brake caliper bracket 

1

 

• washer
• brake caliper bracket bolt 

2

 

NOTE:

Temporarily tighten the brake caliper bracket
bolt.

7. Install: 

• collars
• rear wheel
• adjusting plates
• rear wheel axle
• washer
• wheel axle nut

NOTE:

Temporarily tighten the wheel axle nut.

8. Adjust: 

• drive belt slack

Refer to “ADJUSTING THE DRIVE BELT
SLACK” in chapter 3.

9. Tighten: 

• wheel axle nut

• brake caliper bracket bolts

T

 

R

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.

150 Nm (15.0 m  •  kg, 110 ft  •  lb)

T

 

R

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30 Nm (3.0 m  •  kg, 22 ft  •  lb)

10.Install: 

• brake pad springs
• brake pad shims
• brake pads
• pin boots

11.Install: 

• brake caliper 

1

1

T

 

R

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27 Nm (2.7 m  •  kg, 19 ft  •  lb)

4 - 21

CHAS

REAR WHEEL, BRAKE DISC, AND REAR WHEEL

PULLEY

12.Install: 

• upper drive belt cover plate 

1

• upper drive belt cover 

2

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7 Nm (0.7 m  •  kg, 5.1 ft  •  lb)

T

 

R

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7 Nm (0.7 m  •  kg, 5.1 ft  •  lb)

13.Install: 

• rear fender bracket 

1

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R

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.

40 Nm (4.0 m  •  kg, 29 ft  •  lb)

14.Install: 

• rear fender assembly 

1

15.Connect: 

• tail sub-wire harness coupler 

2

16.Install: 

• seat 

Refer to “SEAT AND SIDE COVERS” in
chapter 3.

4 - 22

CHAS

REAR WHEEL, BRAKE DISC, AND REAR WHEEL

PULLEY

EAS00575

ADJUSTING THE REAR WHEEL STATIC 
BALANCE

NOTE:

_ 

• After replacing the tire, wheel or both, the

rear wheel static balance should be adjusted. 

• Adjust the rear wheel static balance with the

brake disc and rear wheel drive hub
installed. 

1. Adjust: 

• rear wheel static balance 

Refer to “FRONT WHEEL AND BRAKE
DISCS”.

4 - 23

CHAS

FRONT AND REAR BRAKES

EAS00577

FRONT AND REAR BRAKES

FRONT BRAKE PADS

3

2

6

5

5

6

4

1

1

T

 

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6 Nm (0.6 m

 

•

 

kg, 4.3 ft

 

•

 

Ib)

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40 Nm (4.0 m 

•

 

kg, 29 ft

 

•

 

Ib)

Order

Job/Part

Q’ty

Remarks

Removing the front brake pads 

Remove the parts in the order listed. 
The following procedure applies to both
of the front brake calipers.

1

Brake caliper bolt

2

2

Brake pad clip

2

3

Brake pad pin

1

4

Brake pad spring

1

5

Brake  pad

2

6

Brake pad shim

2

For installation, reverse the removal 
procedure.

4 - 24

CHAS

FRONT AND REAR BRAKES

EAS00578

REAR BRAKE PADS

1

1

2

5

4

4

3

5

T

 

R

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27 Nm (2.7 m 

•

 

kg, 19 ft

 

•

 

Ib)

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6 Nm (0.6 m

 

•

 

kg, 4.3 ft

 

•

 

Ib)

Order

Job/Part

Q’ty

Remarks

Removing the rear brake pads 

Remove the parts in the order listed. 

1

Brake caliper retaining bolt

2

2

Brake caliper

1

3

Brake  pad

2

4

Brake pad shim

2

5

Brake pad spring

2

For installation, reverse the removal 
procedure.

4 - 25

CHAS

EAS00579

CAUTION:

_ 

Disc brake components rarely require dis-
assembly. 
Therefore, always follow these preventive
measures: 
• Never disassemble brake components

unless absolutely necessary. 

• If any connection on the hydraulic brake

system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly. 

• Never use solvents on internal brake

components. 

• Use only clean or new brake fluid for

cleaning brake components. 

• Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. 

• Avoid brake fluid coming into contact

with the eyes as it can cause serious
injury. 

FIRST AID FOR BRAKE FLUID ENTERING
THE EYES: 
• Flush with water for 15 minutes and get

immediate medical attention. 

EAS00580

REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake
calipers.

NOTE:

_ 

When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper. 

1. Remove: 

• brake caliper bolts 

1

 

• brake caliper 

2

 

1

1

2

FRONT AND REAR BRAKES

4 - 26

CHAS

2. Remove: 

• brake pad clips 

1

 

• brake pad pin 

2

• brake pad spring 

3

 

1

1

2

3

3. Remove: 

• brake pads 

1

(along with the brake pad shims)

• brake pad shims

1

4. Measure: 

• brake pad wear limit 

a

 

Out of specification 

→

 Replace the brake

pads as a set.

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. 

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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.

Brake pad wear limit 

0.5 mm (0.02 in)

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Bleed screw 

6 Nm (0.6 m • kg, 4.3 ft • lb)

2

1

FRONT AND REAR BRAKES

4 - 27

CHAS

d. Install new brake pads and a new brake pad

spring.

NOTE:

_ 

The arrow 

a

 on the brake pad spring must

point in the direction of disc rotation. 

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6. Install: 

• brake caliper
• brake caliper bolts

7. Check: 

• brake fluid level 

Below the minimum level mark 

a

 

→

 Add

the recommended brake fluid to the proper
level. 
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

8. Check: 

• brake lever operation 

Soft or spongy feeling 

→

 Bleed the brake

system. 
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

T

 

R

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27 Nm (2.7 m  •  kg, 19 ft  •  lb)

EAS00583

REPLACING THE REAR BRAKE PADS

NOTE:

_ 

When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper. 

1. Remove: 

• brake caliper retaining bolts 

1

 

• brake caliper 

2

2

1

FRONT AND REAR BRAKES

4 - 28

CHAS

2. Remove: 

• brake pads 

1

 

(along with the brake pad shims)

• brake pad springs

1

3. Measure: 

• brake pad wear limit 

a

 

Out of specification 

→

 Replace the brake

pads as a set.

4. Install: 

• brake pad springs
• brake pad shims 

(onto the brake pads) 

• brake pads 

NOTE:

_ 

Always install new brake pads, brake pad
shims, and a brake pad spring as a set. 

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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 piston into the brake caliper with
your finger. 

c. Tighten the bleed screw.

d. Install a new brake pad shim 

3

 onto each

new brake pad 

4

.

e. Install new brake pads.

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Brake pad wear limit 

0.8 mm (0.03 in)

T

 

R

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Bleed screw 

6 Nm (0.6 m • kg, 4.3 ft • lb)

a

2

1

4

3

3

FRONT AND REAR BRAKES

4 - 29

CHAS

FRONT AND REAR BRAKES

5. Install: 

• brake caliper retaining bolt 

1

 

1

6. Check: 

• brake fluid level 

Below the minimum level mark 

a

 

→

 Add

the recommended brake fluid to the proper
level. 
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.

7. Check: 

• brake pedal operation 

Soft or spongy feeling 

→

 Bleed the brake

system. 
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.

a

4 - 30

CHAS

FRONT AND REAR BRAKES

EAS00584

FRONT BRAKE MASTER CYLINDER

Order

Job/Part

Q’ty

Remarks

Removing the front brake master 
cylinder 

Remove the parts in the order listed. 

Brake fluid

Drain.

1

Rear view mirror (right)

1

2

Brake master cylinder reservoir cap

1

3

Brake master cylinder reservoir 
diaphragm holder

1

4

Brake master cylinder reservoir 
diaphragm

1

5

Brake lever

1

6

Brake lever spring

1

4 - 31

CHAS

FRONT AND REAR BRAKES

Order

Job/Part

Q’ty

Remarks

7

Front brake light switch connector

2

Disconnect. Refer to “REMOVING THE 

FRONT BRAKE MASTER 
CYLINDER” and “ASSEM-
BLING AND INSTALLING 
THE FRONT BRAKE MAS-
TER CYLINDER”.

8

Union bolt

1

9

Brake hose

1

Disconnect.

10

Copper washer

2

11

Brake master cylinder holder

1

12

Brake master cylinder

1

13

Front brake light switch

1

For installation, reverse the removal 
procedure.

4 - 32

CHAS

FRONT AND REAR BRAKES

EAS00585

Order

Job/Part

Q’ty

Remarks

Disassembling the front brake 
master cylinder 

Remove the parts in the order listed. 

1

 Dust 

boot

1

Refer to “ASSEMBLING AND INSTALL-
ING THE FRONT BRAKE MASTER CYL-
INDER”.

2

 Circlip

1

3

 

Brake master cylinder kit

1

4

 

Brake master cylinder

1

For assembly, reverse the disassembly 
procedure.