Yamaha XV1700P, XV1700PC. Service Manual - part 15

4 - 49

CHAS

EAS00633

CHECKING THE FRONT AND REAR 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 disassem-
bled

1. Check: 

• brake caliper pistons 

1

 

Rust/scratches/wear 

→

 Replace the brake

caliper pistons. 

• brake caliper cylinders 

2

 

Scratches/wear 

→

 Replace the brake cali-

per assembly. 

• brake caliper body 

Cracks/damage 

→

 Replace the brake cali-

per assembly. 

• brake fluid delivery passages 

(brake caliper body) 
Obstruction 

→

 Blow out with compressed

air.

WARNING

_ 

Whenever a brake caliper is disassembled,
replace the brake caliper piston seals. 

È

Front 

É

Rear

2. Check: 

• rear brake caliper bracket 

1

 

Cracks/damage 

→

 Replace.

È

1

2

É

1

FRONT AND REAR BRAKES

4 - 50

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 com-

ponents 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 disassem-

bled, replace the brake caliper piston
seals. 

Recommended brake fluid 

DOT 4

1. Install: 

• brake caliper 

1

 

(temporarily) 

• copper washers 

2

 

• brake hose 

3

 

• union bolt 

4

WARNING

_ 

Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2. 

CAUTION:

_ 

When installing the brake hose onto the
brake caliper 

1

, make sure the brake pipe

a

 touches the projection 

b

 on the brake

caliper. 

2. Remove: 

• brake caliper

New

T

 

R

.

.

32 Nm (3.2 m  •  kg, 23 ft  •  lb)

FRONT AND REAR BRAKES

4 - 51

CHAS

3. Install: 

• brake pads 
• brake pad spring 
• brake caliper bolt

• brake hose holder 

T

 

R

.

.

40 Nm (4.0 m  •  kg, 29 ft  •  lb)

T

 

R

.

.

8 Nm (0.8 m  •  kg, 5.8 ft  •  lb)

4. Fill: 

• brake master cylinder reservoir 

(with the specified amount of the recom-
mended brake fluid)

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. 

• When refilling, be careful that water does

not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock. 

CAUTION:

_ 

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. 

5. Bleed: 

• brake system 

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

Recommended brake fluid 

DOT 4

FRONT AND REAR BRAKES

4 - 52

CHAS

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 lever operation 

Soft or spongy feeling 

→

 Bleed the brake

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

EAS00642

ASSEMBLING AND INSTALLING THE 
REAR BRAKE CALIPER

WARNING

_ 

• Before installation, all internal brake com-

ponents 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 disassem-

bled, replace the brake caliper piston
seals. 

Recommended brake fluid 

DOT 4

FRONT AND REAR BRAKES

4 - 53

CHAS

FRONT AND REAR BRAKES

1. Install: 

• brake caliper 

1

 

(temporarily) 

• copper washers 

2

 

• brake hose 

3

 

• union bolt 

4

 

WARNING

_ 

Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2. 

CAUTION:

_ 

When installing the brake hose onto the
brake caliper 

1

, make sure the brake pipe

a

 touches the projection 

b

 on the brake

caliper. 

b

1

4

3

2

New

a

New

T

 

R

.

.

30 Nm (3.0 m  •  kg, 22 ft  •  lb)

2. Remove: 

• brake caliper 

3. Install: 

• brake pad springs 
• brake pad 
• brake caliper 
• brake caliper retaining bolts 

T

 

R

.

.

27 Nm (2.7 m  •  kg, 19 ft  •  lb)

4 - 54

CHAS

FRONT AND REAR BRAKES

4. Fill: 

• brake fluid reservoir 

(with the specified amount of the recom-
mended brake fluid)

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. 

• When refilling, be careful that water does

not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock. 

CAUTION:

_ 

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately. 

5. Bleed: 

• brake system 

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

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.

Recommended brake fluid 

DOT 4

a

4 - 55

CHAS

FRONT FORK

EAS00647

FRONT FORK

3

6

2

5

4

1

T

 

R

.

.

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

.

.

16 Nm (1.6 m 

•

 

kg, 11 ft

 

•

 

Ib)

T

 

R

.

.

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

T

 

R

.

.

26 Nm (2.6 m 

•

 

kg, 19 ft

 

•

 

Ib)

T

 

R

.

.

23 Nm (2.3 m 

•

 

kg, 17 ft

 

•

 

Ib)

Order

Job/Part

Q’ty

Remarks

Removing the front fork legs 

Remove the parts in the order listed. 
The following procedure applies to both
of the front fork legs.

Front wheel

Refer  to  “FRONT WHEEL AND BRAKE
DISCS”. 

1

Front fender

1

2

Upper bracket pinch bolt

2

Loosen.

Refer to “REMOVING THE 
FRONT FORK LEGS” and 
“INSTALLING THE FRONT 
FORK LEGS”.

3

Cap bolt

1

Loosen.

4

Turn signal light bracket pinch bolt

1

Loosen.

5

Lower bracket pinch bolt

2

Loosen.

6

Front fork leg

1

For installation, reverse the removal 
procedure.

4 - 56

CHAS

FRONT FORK

EAS00648

Order

Job/Part

Q’ty

Remarks

Disassembling the front fork legs 

Remove the parts in the order listed. 
The following procedure applies to both
of the front fork legs.

1

 Cap 

bolt

1

Refer to “DISASSEMBLING THE FRONT 
FORK LEGS” and “ASSEMBLING THE 
FRONT FORK LEGS”.

2

 O-ring

1

3

 Spacer

1

4

 Nut

1

5

 Spring 

seat

1

6

 Fork 

spring

1

7

 Outer 

tube

1

8

 Dust 

seal

1

4 - 57

CHAS

FRONT FORK

Order

Job/Part

Q’ty

Remarks

9

 

Oil seal clip

1

Refer to “DISASSEMBLING THE FRONT 
FORK LEGS” and “ASSEMBLING THE 
FRONT FORK LEGS”.

0

 Oil 

seal

1

A

 Washer

1

B

 

Damper rod assembly bolt

1

C

 Copper 

washer

1

D

 Damper 

rod 

assembly

1

E

 Inner 

tube

1

For assembly, reverse the disassembly 
procedure.

4 - 58

CHAS

FRONT FORK

EAS00649

REMOVING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
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 front wheel is elevated. 

2. Loosen: 

• upper bracket pinch bolts 

1

 

• cap bolt 

2

 

• turn signal light bracket pinch bolt 

3

• lower bracket pinch bolts 

4

WARNING

_ 

Before loosening the upper and lower
bracket pinch bolts and turn signal light
bracket pinch bolt, support the front fork
leg. 

3. Remove: 

• front fork leg

2

1

4

3

EAS00655

DISASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Remove: 

• cap bolt 

1

 

(from the damper rod)

• spacer 

2

 

• nut 

3

 

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Press down on the spacer with the fork

spring compressor 

4

. 

b. Install the rod holder 

5

 between the nut 

3

and the spacer 

2

. 

Fork spring compressor

YM-01441

Rod holder

YM-01434

4 - 59

CHAS

FRONT FORK

NOTE:

_ 

Use the side of the rod holder that is marked
“B”. 

c. Loosen the nut. 
d. Remove the cap bolt.
e. Remove the rod holder and fork spring com-

pressor.

WARNING

_ 

The fork spring is compressed. 

f. Remove the spacer and nut.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

2. Drain: 

• fork oil

NOTE:

_ 

Stroke the damper rod 

1

 several times while

draining the fork oil. 

3. Remove: 

• dust seal 
• oil seal clip 

1

 

• oil seal
• washer

(with a flat-head screwdriver)

CAUTION:

_ 

Do not scratch the inner tube. 

4 - 60

CHAS

FRONT FORK

4. Remove: 

• damper rod assembly bolt 
• copper washer

NOTE:

_ 

While holding the damper rod with the damper
rod holder 

1

, loosen the damper rod assem-

bly bolt. 

Damper rod holder 

YM-01423

EAS00657

CHECKING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
1. Check: 

• inner tube 

1

 

• outer tube 

2

 

Bends/damage/scratches 

→

 Replace.

WARNING

_ 

Do not attempt to straighten a bent inner
tube as this may dangerously weaken it. 

2. Measure: 

• spring free length 

a

 

Out of specification 

→

 Replace.

Spring free length 

296 mm (11.65 in) 
<Limit>: 291 mm (11.46 in)

4 - 61

CHAS

FRONT FORK

3. Check: 

• damper rod 

1

 

Damage/wear 

→

 Replace. 

Obstruction 

→

 Blow out all of the oil pas-

sages with compressed air. 

CAUTION:

_ 

• The front fork leg has a built-in damper

adjusting rod and a very sophisticated
internal construction, which are particu-
larly sensitive to foreign material. 

• When disassembling and assembling the

front fork leg, do not allow any foreign
material to enter the front fork. 

4. Check: 

• cap bolt O-ring 

Damage/wear 

→

 Replace.

4 - 62

CHAS

FRONT FORK

EAS00660

ASSEMBLING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.

WARNING

_ 

• Make sure the oil levels in both front fork

legs are equal. 

• Uneven oil levels can result in poor han-

dling and a loss of stability. 

NOTE:

_ 

• When assembling the front fork leg, be sure

to replace the following parts: 

- inner tube bushing 
- outer tube bushing 
- oil seal 
- dust seal 

• Before assembling the front fork leg, make

sure all of the components are clean. 

1. Install: 

• damper rod assembly 

1

CAUTION:

_ 

Allow the damper rod assembly to slide
slowly down the inner tube 

2

 until it pro-

trudes from the bottom of the inner tube.
Be careful not to damage the inner tube. 

2. Tighten: 

• damper rod assembly bolt 

1

NOTE:

_ 

While holding the damper rod assembly with
the damper rod holder 

2

, tighten the damper

rod assembly bolt. 

Damper rod holder 

YM-01423

T

 

R

.

.

40 Nm (4.0 m  •  kg, 29 ft  •  lb)

4 - 63

CHAS

FRONT FORK

3. Install: 

• dust seal 

1

 

• oil seal clip 

2

• oil seal 

3

• washer 

4

CAUTION:

_ 

Make sure the numbered side of the oil seal
faces down. 

NOTE:

_ 

• Before installing the oil seal, lubricate its lips

with lithium-soap-based grease. 

• Lubricate the outer surface of the inner tube

with fork oil. 

• Before installing the oil seal, cover the top of

the front fork leg with a plastic bag 

5

 to pro-

tect the oil seal during installation. 

4. Install: 

• outer tube

(onto the inner tube)

5. Install: 

• washer 
• oil seal 

1

 

(with the fork seal driver 

2

)

Fork seal driver 

YM-01442

6. Install: 

• oil seal clip 

1

NOTE:

_ 

Adjust the oil seal clip so that it fits into the
outer tube’s groove. 

4 - 64

CHAS

FRONT FORK

7. Install: 

• dust seal 

1

 

(with the fork seal driver 

2

)

8. Install: 

• rod puller 

1

 

(onto the damper rod 

2

)

Rod puller 

YM-01437

9. Fully compress the front fork leg.
10.Fill: 

• front fork leg 

(with the specified amount of the recom-
mended fork oil)

CAUTION:

_ 

• Be sure to use the recommended fork oil.

Other oils may have an adverse effect on
front fork performance. 

• When disassembling and assembling the

front fork leg, do not allow any foreign
material to enter the front fork. 

Quantity (each front fork leg) 

476 cm

3

 (16.8 Imp qt, 16.1 US qt)

Recommended oil 

Yamaha suspension oil “01” 

11.After filling the front fork leg, slowly stroke

the damper rod 

1

 up and down (at least ten

times) to distribute the fork oil.

NOTE:

_ 

Be sure to stroke the damper rod slowly
because the fork oil may spurt out.