Yamaha XV1700P, XV1700PC. Service Manual - part 19

5 - 22

ENG

INSTALLING THE ROCKER ARMS AND 
PUSH RODS

The following procedure applies to both cylin-
ders.
1. Install:

• rocker arms 

1

• rocker arm shafts 

2

(onto rocker arm base)

NOTE:

The thread hole 

a

 of the rocker arm shaft

must face to the outside.

2. Install:

• dowel pins 

1

• rocker arm gasket 

2

New

3. Install:

• rocker arm bass

(with rocker arms)

• push rods

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Put the rocker arm base on the cylinder

head.

b. Install the push rods.

NOTE:

• Be sure to correctly install the push rods

between the rocker arms and valve lifters as
shown. The illustration is viewed from the
right side of the motorcycle.

È

Rear cylinder

É

Front cylinder

1

Intake side rocker arm

2

Exhaust side rocker arm

3

Intake valve lifter

4

Exhaust valve lifter

5

Push rod 2 

= 288.5 mm (11.358 in) blue paint-

ing

6

Push rod 1 

= 290.5 mm (11.437 in) yellow

painting

• The lengths of push rod 1 and push rod 2 are

different. Therefore, be sure to install them in
the proper position.

• Lubricate the push rod end balls with engine

oil.

È

É

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

5 - 23

ENG

c. Install the rocker arm base bolts.

NOTE:

Tighten the rocker arm base bolts in stages
and in a crisscross pattern.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

T

 

R

.

.

Rocker arm base bolt 

1

10 Nm (1.0 m • kg, 7.2 ft • lb)

Rocker arm base bolt 

2

24 Nm (2.4 m • kg, 17 ft • lb)

INSTALLING THE CYLINDER HEAD 
COVERS

The following procedure applies to both cylin-
ders.
1. Install:

• dowel pins 

1

 

• cylinder head cover gasket 

2

New

2. Install:

• cylinder head cover 

1

 

Bolts 

2

: = 40 mm (1.57 in)

Bolts 

3

: = 50 mm (1.97 in)

Bolts 

4

: = 60 mm (2.36 in)

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

INSTALLING THE CAMSHAFT SPROCKET 
COVER AND ENGINE LEFT SIDE COVER

1. Install:

• dowel pins 

1

 

• camshaft sprocket cover gasket 

2

New

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

5 - 24

ENG

2. Install:

• canister (for California only)

NOTE:

Refer to “CABLE ROUTING” in chapter 2.

3. Install:

• spark plugs

4. Connect:

• spark plug caps

NOTE:

Refer to “CABLE ROUTING” in chapter 2.

È

Forward

1

Ignition coil 1 - L spark plug lead

2

Ignition coil 1 - R spark plug lead

3

Ignition coil 2 - L spark plug lead

4

Ignition coil 2 - R spark plug lead

5. Adjust:

• installed shift rod length

Refer to “ADJUSTING THE SHIFT PEDAL”
in chapter 3.

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS

5 - 25

ENG

EAS00196

CAMSHAFTS

14

11

13

12

12

10

9

7

3

2

8

5

6

4

1

(6)

T

 

R

.

.

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

.

.

30 Nm (3.0 m 

•

 

kg, 22 ft

 

•

 

Ib)

T

 

R

.

.

52 Nm (5.2 m 

•

 

kg, 37 ft

 

•

 

Ib)

New

M

M

Order

Job/Part

Q’ty

Remarks

Removing the camshafts 

Remove the parts in the order listed. 

Valve lifters

Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”. 

1

Decompression solenoid

1

2

Long decompression push rod

1

92 mm (3.6 in)

3

Short decompression push rod

1

78 mm (3.1 in)

4

Front cylinder camshaft end cover

1

Refer to “REMOVING THE CAM-
SHAFTS” and “INSTALLING THE CAM-
SHAFTS”.

5

Camshaft drive gear

1

6

Straight key

1

CAMSHAFTS

5 - 26

ENG

CAMSHAFTS

14

11

13

12

12

10

9

7

3

2

8

5

6

4

1

(6)

T

 

R

.

.

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

T

 

R

.

.

30 Nm (3.0 m 

•

 

kg, 22 ft

 

•

 

Ib)

T

 

R

.

.

52 Nm (5.2 m 

•

 

kg, 37 ft

 

•

 

Ib)

New

M

M

Order

Job/Part

Q’ty

Remarks

7

Camshaft driven gear

1

Refer to “REMOVING THE CAM-
SHAFTS” and “INSTALLING THE CAM-
SHAFTS”.

8

Straight key

1

9

Oil delivery pipe

1

10

Camshaft cover

1

11

Camshaft cover gasket

1

12

Dowel pin

2

13

Front cylinder camshaft

1

14

Rear cylinder camshaft

1

For installation, reverse the removal 
procedure.

5 - 27

ENG

CAMSHAFTS

REMOVING THE CAMSHAFTS

1. Loosen: 

• front cylinder camshaft end cover bolts 

1

 

• camshaft drive gear bolt 

2

 

NOTE:

_ 

• Place a folded copper washer 

3

 between

the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.

• Do not damage the teeth of the camshaft

drive and camshaft driven gears.

2. Loosen: 

• camshaft driven gear nut 

1

 

NOTE:

_ 

• Place a folded copper washer 

2

 between

the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.

• Do not damage the teeth of the camshaft

drive and camshaft driven gears.

3. Remove: 

• front cylinder camshaft end cover
• camshaft drive gear 

1

• camshaft driven gear 

2

• straight keys 

NOTE:

_ 

Cover the crankcase hole with a clean rag 

3

to prevent the straight keys from falling into the
crankcase. 

4. Remove: 

• oil delivery pipe 

1

• camshaft cover 

2

 

(along with the camshafts)

NOTE:

_ 

Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them. 

5 - 28

ENG

CAMSHAFTS

EAS00204

CHECKING THE CAMSHAFTS

1. Check: 

• cam 

Blue discoloration/pitting/scratches 

→

 

Replace the camshaft.

2. Measure: 

• cam dimensions 

a

 and 

b

 

Out of specification 

→

 Replace the cam-

shaft.

3. Measure: 

• camshaft journal diameter (crankcase side)

a

 

Out of specification 

→

 Replace the cam-

shaft. 

4. Measure: 

• camshaft journal diameter (camshaft cover

side) 

b

 

Out of specification 

→

 Replace the cam-

shaft. 

Camshaft lobe dimension limit 

Intake camshaft 

a

38.231 ~ 38.331 mm 
(1.5052 ~ 1.5091 in) 

b

32.013 ~ 32.113 mm 
(1.2604 ~ 1.2643 in) 

Exhaust camshaft 

a

38.232 ~ 38.332 mm 
(1.5052 ~ 1.5091 in) 

b

31.995 ~ 32.095 mm 
(1.2596 ~

 

1.2636 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)

5 - 29

ENG

CAMSHAFTS

5. Measure: 

• crankcase hole inside diameter 

c

 

Out of specification 

→

 Replace the crank-

case. 

Crankcase hole inside diameter

25.000 ~ 25.021 mm 
(0.9843 ~ 0.9851 in)

6. Measure: 

• camshaft cover hole inside diameter 

d

 

Out of specification 

→

 Replace the cam-

shaft cover. 

Camshaft cover hole inside 
diameter

28.000 ~ 28.021 mm 
(1.1024 ~ 1.1032 in)

7. Calculate: 

• camshaft-to-crankcase clearance

Out of specification 

→

 Replace the defec-

tive part(s). 

NOTE:

Calculate the clearance by subtracting the
crankcase side camshaft journal diameter
(crankcase side) from the crankcase hole
inside diameter.

8. Calculate: 

• camshaft to camshaft cover clearance

Out of specification 

→

 Replace the defec-

tive part(s). 

NOTE:

Calculate the clearance by subtracting the
camshaft journal diameter (camshaft cover
side) from the camshaft cover hole inside
diameter.

Camshaft to crankcase clearance

0.050 ~ 0.084 mm 
(0.0020 ~ 0.0033 in)

Camshaft to camshaft cover 
clearance

0.020 ~ 0.054 mm 
(0.0008 ~ 0.0021 in)

5 - 30

ENG

CAMSHAFTS

9. Check: 

• camshaft drive gears
• camshaft driven gears

Chips/pitting/roughness/wear 

→

 Replace 

the defective part(s). 

CHECKING THE DECOMPRESSION 
SYSTEM

1. Check: 

• decompression system

NOTE:

_ 

• Check the decompression system while the

decompression push rod is installed in the
camshaft.

• Check that the decompression pin 

1

projects from the camshaft.

• Check that the decompression push rod 

2

moves smoothly.

2. Check: 

• decompression push rods

Bends/damage 

→

 Replace. 

CHECKING THE OIL DELIVERY PIPE

1. Check: 

• oil delivery pipe 

1

 

Damage 

→

 Replace. 

Obstruction 

→

 Wash and blow out with 

compressed air. 

• O-rings 

2

 

Damage/wear 

→

 Replace. 

5 - 31

ENG

CAMSHAFTS

INSTALLING THE CAMSHAFTS

1. Install: 

• camshafts

(to the camshaft cover)

• front cylinder camshaft end cover

NOTE:

_ 

• Lubricate molybdenum disulfide oil onto the

camshaft journals and lobes. 

• Align the punch mark 

a

 on the rear cylinder

camshaft with the punch mark 

b

 on the front

cylinder camshaft.

2. Install: 

• dowel pins 

1

 

• camshaft cover gasket 

2

New

3. Install: 

• camshaft cover 

1

 

(along with the camshafts)

• oil delivery pipe 

2

 

NOTE:

_ 

Tighten the camshaft cover bolts in stages and
in a crisscross pattern. 

5 - 32

ENG

CAMSHAFTS

4. Install: 

• front cylinder camshaft end cover 

1

 

NOTE:

_ 

• Align the projection 

a

 on the front cylinder

camshaft end cover with the hole 

b

 on the

front cylinder camshaft.

• Finger tighten the place bolts.

5. Install: 

• straight keys 
• camshaft drive gear 

1

 

• camshaft driven gear 

2

 

NOTE:

_ 

• Cover the crankcase hole with a clean rag 

3

to prevent the straight keys from falling into
the crankcase.

• Align the punch mark 

a

 on the camshaft

drive gear 

1

 with the punch mark 

b

 on the

camshaft driven gear 

2

.

• Insert a cross-headed screwdriver into one of

the holes in the outer camshaft driven gear
and rotate the gear until the teeth of both
driven gears are aligned. The teeth of both
camshaft driven gears must be aligned for
installation.

5 - 33

ENG

CAMSHAFTS

6. Tighten: 

• camshaft driven gear nut 

1

 

NOTE:

_ 

• Place a folded copper washer 

2

 between

the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.

• Do not damage the teeth of the camshaft

drive and camshaft driven gear.

• After tightening the camshaft driven gear nut,

remove the copper washer to clean the teeth
of the camshaft drive gear and camshaft
driven gear.

T

 

R

.

.

52 Nm (5.2 m  •  kg, 37 ft  •  lb)

7. Tighten: 

• camshaft drive gear bolt 

1

 

• front cylinder camshaft end cover bolts 

2

 

NOTE:

_ 

• Place a folded copper washer 

3

 between

the teeth of the camshaft drive gear and
camshaft driven gear in order to lock them.

• Do not damage the teeth of the camshaft

drive and camshaft driven gear.

• After tightening the camshaft drive gear bolt,

remove the copper washer to clean the teeth
of the camshaft drive gear and camshaft
driven gear.

T

 

R

.

.

30 Nm (3.0 m  •  kg, 22 ft  •  lb)

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

5 - 34

ENG

CYLINDER HEADS

EAS00221

CYLINDER HEADS

9

10

5

3

3

7

8

1

4

2

8

8

7

6

T

 

R

.

.

60 Nm (6.0 m 

•

 

kg, 43 ft

 

•

 

Ib)

T

 

R

.

.

39 Nm (3.9 m 

•

 

kg, 28 ft

 

•

 

Ib)

T

 

R

.

.

18 Nm (1.8 m 

•

 

kg, 13 ft

 

•

 

Ib)

T

 

R

.

.

21 Nm (2.1 m 

•

 

kg, 15 ft

 

•

 

Ib)

E

E

New

New

New

New

New

T

 

R

.

.

20 Nm (2.0 m 

•

 

kg, 14 ft

 

•

 

Ib)

New

T

 

R

.

.

20 Nm (2.0 m 

•

 

kg, 14 ft

 

•

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

Order

Job/Part

Q’ty

Remarks

Removing the cylinder heads

Remove the parts in the order listed. 

Throttle bodies/intake manifolds

Refer  to  “THROTTLE BODIES” in chap-
ter 6. 

Air cut-off valve assembly

Refer to “AIR CUT-OFF VALVE ASSEM-
BLY AND AIR INDUCTION SYSTEM
HOSES” in chapter 6. 

Rocker arms/cylinder head covers

Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS”. 

1

Engine temperature sensor

1

Refer to “INSTALLING THE CYLINDER 
HEAD”.

2

Oil delivery pipe

1

3

Copper washer

4

4

Copper washer

2

5 - 35

ENG

CYLINDER HEADS

9

10

5

3

3

7

8

1

4

2

8

8

7

6

T

 

R

.

.

60 Nm (6.0 m 

•

 

kg, 43 ft

 

•

 

Ib)

T

 

R

.

.

39 Nm (3.9 m 

•

 

kg, 28 ft

 

•

 

Ib)

T

 

R

.

.

18 Nm (1.8 m 

•

 

kg, 13 ft

 

•

 

Ib)

T

 

R

.

.

21 Nm (2.1 m 

•

 

kg, 15 ft

 

•

 

Ib)

E

E

New

New

New

New

New

T

 

R

.

.

20 Nm (2.0 m 

•

 

kg, 14 ft

 

•

 

Ib)

New

T

 

R

.

.

20 Nm (2.0 m 

•

 

kg, 14 ft

 

•

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

Order

Job/Part

Q’ty

Remarks

5

Rear cylinder head

1

Refer to “REMOV-
ING THE CYLIN-
DER HEADS”.

Refer to “INSTALL-
ING THE CYLIN-
DER HEAD”.

6

Front cylinder head

1

7

Cylinder head gasket

2

8

Dowel pin

4

9

Rear exhaust pipe joint cover

1

10

Rear exhaust pipe joint

1

For installation, reverse the removal 
procedure.

5 - 36

ENG

CYLINDER HEADS

REMOVING THE CYLINDER HEADS

1. Remove: 

• cylinder head

NOTE:

_ 

• Loosen the nuts in the proper sequence.
• Follow the numerical order shown in the illus-

tration. Loosen each bolt 1/4 of a turn at a
time until all of the nuts are loose.

EAS00228

CHECKING THE CYLINDER HEADS

The following procedure applies to each cylin-
der heads.
1. Eliminate: 

• combustion chamber carbon deposits 

(with a rounded scraper)

NOTE:

_ 

Do not use a sharp instrument to avoid damag-
ing or scratching: 
• spark plug bore threads 
• valve seats 

2. Check: 

• cylinder head 

Damage/scratches 

→

 Replace.

3. Measure: 

• cylinder head warpage 

Out of specification 

→

 Resurface the cylin-

der head.

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Place a straightedge and a thickness gauge

across the cylinder head. 

b. Measure the warpage. 
c. If the limit is exceeded, resurface the cylin-

der head as follows. 

d. Place a 400 ~ 600 grit wet sandpaper on

the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.

NOTE:

_ 

To ensure an even surface, rotate the cylinder
head several times. 

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

Maximum cylinder head warpage 

0.03 mm (0.0012 in)

5 - 37

ENG

CYLINDER HEADS

CHECKING THE OIL DELIVERY PIPE

1. Check: 

• oil delivery pipe 

1

 

Damage 

→

 Replace.

Obstruction 

→

 Wash and blow out with

compressed air.

EAS00232

INSTALLING THE CYLINDER HEAD

1. Install: 

• cylinder head gasket 

1

 

• dowel pins 

2

 

2. Install: 

• cylinder heads
• washers

New

3. Tighten: 

• cylinder head nuts (M12: 1 ~ 4)

• cylinder head nuts (M10: 5 ~ 6)

NOTE:

_ 

• Lubricate the cylinder head nuts with engine

oil. 

• Tighten the cylinder head nuts in the proper

tightening sequence as shown and torque
them in two stages. 

T

 

R

.

.

60 Nm (6.0 m  •  kg, 43 ft  •  lb)

T

 

R

.

.

39 Nm (3.9 m  •  kg, 28 ft  •  lb)

5. Install: 

• copper washers

 

• oil delivery pipe 

1

 

• oil delivery pipe bolts (M10)

• oil delivery pipe bolts (M8)

New

T

 

R

.

.

21 Nm (2.1 m  •  kg, 15 ft  •  lb)

T

 

R

.

.

18 Nm (1.8 m  •  kg, 13 ft  •  lb)