Yamaha XV1700P, XV1700PC. Service Manual - part 16

 

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Yamaha XV1700P, XV1700PC. Service Manual - part 16

 

 

4 - 65

CHAS

FRONT FORK

12.Slowly stroke the outer tube 

1

 up and

down to distribute the fork oil once more
(1 stroke = about 150 mm (8.12 in)).

NOTE:

Be careful not to stroke the outer tube over
150 mm (8.12 in) as this will cause air to enter.
If the outer tube is stroke more than 150 mm
(8.12 in), repeat steps (11) and (12). 

13.Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.

NOTE:

Be sure to bleed the front fork leg of any resid-
ual air. 

14.Measure: 

• front fork leg oil level 

a

 

Out of specification 

 Correct.

Front fork leg oil level (from the 
top of the outer tube and damper 
rod, with the outer tube fully com-
pressed, and without the spring)

100 mm (3.94 in)

4 - 66

CHAS

FRONT FORK

15.Install: 

• nut 

1

 

• fork spring 

2

 

• spring seat 

3

 

• spacer 

4

 

• cap bolt 

5

▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼▼▼

a. Remove the rod puller. 
b. Install the nut 

1

c. Install the rod puller onto the damper rod. 

d. Install the fork spring, spring seat, and

spacer. 

NOTE:

Install the spring with the smaller pitch 

a

 fac-

ing up 

È

e. Press down on the spacer with the fork

spring compressor 

6

.

f. Pull up the rod puller and install the rod

holder between the nut 

1

 and the spacer

4

.

NOTE:

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

g. Remove the rod puller. 
h. Install the nut 

1

 and position it as specified

b

i. Hold the nut  and tighten the cap bolt until it

comes into contact with the nut.

j. Hold the cap bolt and tighten the nut to

specification.

Rod puller 

YM-01437

Fork spring compressor

YM-01441

Rod holder 

YM-01434

Distance 

b

15.5 mm (0.61 in)

T

 

R

.

.

Nut 

15 Nm (1.5 m • kg, 11 ft • lb)

4 - 67

CHAS

FRONT FORK

k. Remove the rod holder and fork spring com-

pressor.

CAUTION:

The fork spring is compressed. 
Always use a new cap bolt O-ring.

▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲▲▲

16.Install: 

• cap bolt 

(onto the outer tube)

NOTE:

Temporary tighten the cap bolt. 

EAS00662

INSTALLING THE FRONT FORK LEGS

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

• front fork leg 

Temporarily tighten the upper and lower
bracket pinch bolts.

NOTE:

Make sure the outer fork tube is flush with the
top of the upper bracket. 

2. Tighten: 

• lower bracket pinch bolts 

1

 

• turn signal light bracket pinch bolt 

2

 

• cap bolt 

3

 

• upper bracket pinch bolts 

4

 

WARNING

Make sure the brake hoses are routed prop-
erly. 

1

2

3

4

T

 

R

.

.

23 Nm (2.3 m  •  kg, 17 ft  •  lb)

T

 

R

.

.

7 Nm (0.7 m  •  kg, 5.1 ft  •  lb)

T

 

R

.

.

23 Nm (2.3 m  •  kg, 17 ft  •  lb)

T

 

R

.

.

26 Nm (2.6 m  •  kg, 19 ft  •  lb)

4 - 68

CHAS

FRONT FORK

3. Adjust: 

• spring preload 

Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.

4 - 69

CHAS

EAS00664

HANDLEBAR

Order

Job/Part

Q’ty

Remarks

Removing the handlebar 

Remove the parts in the order listed. 

1

Rear view mirror (left and right)

2

2

Plastic  clamp

6

Refer to “INSTALLING THE 
HANDLEBAR”.

3

Front brake light switch connector

2

Disconnect.

4

Brake master cylinder holder

1

5

Brake master cylinder

1

6

Right handlebar switch

1

7

Throttle cable holder

1

8

Throttle cable

2

Disconnect.

9

Throttle grip

1

10

Clutch switch coupler

1

Disconnect.

HANDLEBAR

4 - 70

CHAS

Order

Job/Part

Q’ty

Remarks

11

Left handlebar switch

1

Refer to “INSTALL-
ING THE HANDLE-
BAR”.

12

Handlebar grip

1

Refer  to  “REMOV-
ING THE HANDLE-
BAR”.

13

Clutch cable

1

Disconnect.

14

Clutch lever holder

1

15

Upper handlebar holder

2

16

Handlebar

1

17

Lower handlebar holder

2

For installation, reverse the removal 
procedure.

HANDLEBAR

4 - 71

CHAS

EAS00666

REMOVING THE HANDLEBAR

1. Stand the motorcycle on a level surface.

WARNING

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

2. Remove: 

• handlebar grip 

1

NOTE:

Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar. 

EAS00668

CHECKING THE HANDLEBAR

1. Check: 

• handlebar 

Bends/cracks/damage 

 Replace.

WARNING

Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it. 

EAS00670

INSTALLING THE HANDLEBAR

1. Stand the motorcycle on a level surface.

WARNING

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

2. Install: 

• washers
• lower handlebar holders 

1

 

NOTE:

Temporarily tighten the nuts 

2

1

2

HANDLEBAR

4 - 72

CHAS

3. Install: 

• handlebar 

1

 

• upper handlebar holders 

2

 

CAUTION:

• First, tighten the bolts on the front side of

the handlebar holder, and then on the rear
side. 

• Turn the handlebar all the way to the left

and right. If there is any contact with the
fuel tank, adjust the handlebar position. 

NOTE:

Align the match marks 

a

 on the handlebar

with the upper surface of the lower handlebar
holder. 

a

2

1

T

 

R

.

.

28 Nm (2.8 m  •  kg, 20 ft  •  lb)

4. Tighten: 

• lower handlebar holder nuts

T

 

R

.

.

40 Nm (4.0 m  •  kg, 29 ft  •  lb)

5. Install: 

• clutch lever holder

NOTE:

Align the slit of clutch lever holder with the
punch mark 

a

 on the handlebar. 

6. Install: 

• clutch cable

NOTE:

Lubricate the end of the clutch cable with a thin
coat of lithium soap base grease. 

HANDLEBAR

4 - 73

CHAS

7. Install: 

• left handlebar switch

NOTE:

Align the end 

a

 of the left handlebar switch

with the punch mark 

b

 on the handlebar. 

8. Connect: 

• clutch switch coupler 

9. Install: 

• handlebar grip

▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼▼▼

a. Apply a thin coat of rubber adhesive onto

the left end of the handlebar. 

b. Slide the handlebar grip over the left end of

the handlebar. 

c. Wipe off any excess rubber adhesive with a

clean rag.

WARNING

Do not touch the handlebar grip until the
rubber adhesive has fully dried. 

▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲▲▲

10.Install: 

• throttle grip

11.Connect: 

• throttle cable

12.Install: 

• right handlebar switch

NOTE:

Align the projection 

a

 on the right handlebar

switch with the hole 

b

 in the handlebar. 

HANDLEBAR

4 - 74

CHAS

13.Install: 

• brake master cylinder
• brake master cylinder holder

NOTE:

• Install the brake master cylinder holder with

the “UP” mark facing up. 

• Align the end of the brake master cylinder

holder with the punch mark 

a

 in the handle-

bar. 

• First, tighten the upper bolt, then the lower

bolt.

14.Connect: 

• front brake light switch connectors

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

15.Install: 

• plastic clamps

NOTE:

Refer to “CABLE ROUTING” in chapter 2. 

16.Adjust: 

• clutch cable free play 

Refer to “ADJUSTING THE CLUTCH
CABLE FREE PLAY” in chapter 3.

Clutch cable free play (at the end 
of the clutch lever) 

10 ~ 15 mm (0.39 ~ 0.59 in)

17.Adjust: 

• throttle cable free play 

Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.

Throttle cable free play (at the 
flange of the throttle grip) 

4 ~ 6 mm (0.16 ~ 0.24 in)

HANDLEBAR

4 - 75

CHAS

EAS00676

STEERING HEAD

7

12

7

4

6

5

5

14

13

17

17

16

15

11

10

9

8

1

2

3

LS

LS

LS

T

 

R

.

.

23 Nm (2.3 m 

 

kg, 17 ft

 

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

 kg, 5.1 ft 

 Ib)

T

 

R

.

.

7 Nm (0.7 m

 

 kg, 5.1 ft 

 Ib)

T

 

R

.

.

1st   52 Nm (5.2 m 

 kg, 37 ft 

 lb)

2nd  4 Nm (0.4 m 

 kg, 2.9 ft 

 lb)

T

 

R

.

.

115 Nm (11.5 m 

 kg, 85 ft 

 lb)

Order

Job/Part

Q’ty

Remarks

Removing the lower bracket 

Remove the parts in the order listed. 

Handlebar/handlebar holders

Refer to “HANDLEBAR”. 

Meter assemblies

Refer  to  “HEADLIGHT AND METER
ASSEMBLIES” in chapter 3. 

Front wheel

Refer  to  “FRONT WHEEL AND BRAKE
DISCS”. 

Front fork legs

Refer to “FRONT FORK”. 

1

Steering stem nut

1

Refer to “INSTALLING THE STEERING 
HEAD”.

2

Upper bracket

1

3

Cable guide

1

4

Headlight bracket

1

5

Brake hose bracket

2

6

Brake hose joint

1

7

Turn signal light bracket assembly

2

STEERING HEAD

4 - 76

CHAS

7

12

7

4

6

5

5

14

13

17

17

16

15

11

10

9

8

1

2

3

LS

LS

LS

T

 

R

.

.

23 Nm (2.3 m 

 

kg, 17 ft

 

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

 kg, 5.1 ft 

 Ib)

T

 

R

.

.

7 Nm (0.7 m

 

 kg, 5.1 ft 

 Ib)

T

 

R

.

.

1st   52 Nm (5.2 m 

 kg, 37 ft 

 lb)

2nd  4 Nm (0.4 m 

 kg, 2.9 ft 

 lb)

T

 

R

.

.

115 Nm (11.5 m 

 kg, 85 ft 

 lb)

Order

Job/Part

Q’ty

Remarks

8

Lock washer

1

Refer to “INSTALL-
ING THE STEER-
ING HEAD”.

9

Upper ring nut

1

10

Rubber washer

1

11

Lower ring nut

1

Refer  to  “REMOV-
ING THE LOWER
BRACKET”.

12

Lower bracket

1

13

Lower bearing

1

14

Lower bearing cover

1

15

Upper bearing cover

1

16

Upper bearing

1

17

Bearing outer race

1

For installation, reverse the removal 
procedure.

STEERING HEAD

4 - 77

CHAS

EAS00677

REMOVING THE LOWER BRACKET

1. Stand the motorcycle on a level surface.

WARNING

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

2. Remove: 

• ring nut 

1

 

(with the spanner wrench 

2

)

WARNING

Securely support the lower bracket so that
there is no danger of it falling. 

Spanner wrench 

YU-33975

EAS00681

CHECKING THE STEERING HEAD

1. Wash: 

• bearings 
• bearing races

Recommended cleaning solvent 

Kerosene

2. Check: 

• bearings 
• bearing races 

Damage/pitting 

 Replace.

STEERING HEAD

4 - 78

CHAS

3. Replace: 

• bearings 
• bearing races

▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼▼▼

a. Remove the bearing races from the steering

head pipe with a long rod 

1

 and hammer. 

b. Remove the bearing race from the lower

bracket with a floor chisel 

2

 and hammer. 

c. Install a new rubber seal and new bearing

races.

CAUTION:

If the bearing race is not installed properly,
the steering head pipe could be damaged. 

NOTE:

• Always replace the bearings and bearing

races as a set. 

• Whenever the steering head is disassem-

bled, replace the rubber seal. 

▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲▲▲

4. Check: 

• upper bracket 
• lower bracket 

(along with the steering stem) 
Bends/cracks/damage 

 Replace.

EAS00683

INSTALLING THE STEERING HEAD

1. Lubricate: 

• upper bearing 
• lower bearing 
• bearing races

Recommended lubricant 

Lithium-soap-based grease

2. Install: 

• lower ring nut 

1

 

• rubber washer 

2

 

• upper ring nut 

3

 

• lock washer 

4

 

Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.

1

2

3

4

STEERING HEAD

4 - 79

CHAS

3. Install: 

• upper bracket 
• steering stem nut

NOTE:

Temporarily tighten the steering stem nut. 

4. Install: 

• front fork legs 

Refer to “FRONT FORK”.

NOTE:

Temporarily tighten the lower bracket pinch
bolts. 

5. Tighten: 

• steering stem nut

T

 

R

.

.

115 Nm (11.5 m  •  kg, 85 ft  •  lb)

STEERING HEAD

4 - 80

CHAS

REAR SHOCK ABSORBER AND SWINGARM

10

6

7

12

11

3

4

5

2

1

14

8

11

13

9

T

 

R

.

.

59 Nm (5.9 m 

 

kg, 43 ft

 

 

Ib)

T

 

R

.

.

125 Nm (12.5 m 

 kg, 90 ft 

 lb)

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

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

LS

Order

Job/Part

Q’ty

Remarks

Removing the rear shock absorber
and swingarm

Remove the parts in the order listed. 

Rear brake master cylinder bracket

Refer to “FRONT AND REAR BRAKES”. 

Rear exhaust pipe

Refer to “ENGINE” in chapter 5. 

Rear wheel

Refer  to  “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL PULLEY”. 

1

Adjusting bolt

2

2

Locknut

2

3

Lower drive belt cover plate

1

4

Spacer

1

5

Lower drive belt cover

1

6

Horn 2 coupler

1

Disconnect.

7

Horn  2

1

REAR SHOCK ABSORBER AND SWINGARM

 

 

 

 

 

 

 

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