Yamaha XV1700P, XV1700PC. Service Manual - part 20

 

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Yamaha XV1700P, XV1700PC. Service Manual - part 20

 

 

5 - 38

ENG

CYLINDER HEADS

6. Install: 

• washer 
• engine temperature sensor 

1

 

T

 

R

.

.

20 Nm (2.0 m  •  kg, 14 ft  •  lb)

5 - 39

ENG

VALVES AND VALVE SPRINGS

EAS00236

VALVES AND VALVE SPRINGS 

5 6

8

3

4

7

2

1

8

3

4

7

2

1

8

3

4

7

2

1

8

3

4

7

2

1

M

E

M

E

New

New

New

New

Order

Job/Part

Q’ty

Remarks

Removing the valves and valve 
springs

Remove the parts in the order listed.

The following procedure applies to both
cylinders.

Cylinder head

Refer to “CYLINDER HEADS”. 

1

Valve cotter

8

Refer to “REMOVING THE VALVES” and 
“INSTALLING THE VALVES”.

2

Upper spring seat

4

3

Outer valve spring

4

4

Inner valve spring

4

5

Intake valve

2

6

Exhaust valve

2

7

Valve stem seal

4

8

Lower spring seat

4

For installation, reverse the removal 
procedure.

5 - 40

ENG

VALVES AND VALVE SPRINGS

EAS00238

REMOVING THE VALVES

The following procedure applies to all of the
valves and related components.

NOTE:

Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal. 

1. Check: 

• valve sealing (for leakage)

Leakage at the valve seat 

 Check the

valve face, valve seat, and valve seat width. 
Refer to “CHECKING THE VALVE SEATS”.

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a. Pour a clean solvent 

a

 into the intake and

exhaust ports. 

b. Check that the valves properly seal. 

NOTE:

There should be no leakage at the valve seat

1

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2. Remove: 

• valve cotters 

NOTE:

Remove the valve cotters by compressing the
valve springs with the valve spring compressor
set 

1

Valve spring compressor set

YM-04019

5 - 41

ENG

VALVES AND VALVE SPRINGS

3. Remove: 

• upper spring seat 

1

 

• outer valve spring 

2

 

• inner valve spring 

3

 

• valve 

4

 

• valve stem seal 

5

 

• lower spring seat 

6

 

NOTE:

Identify the position of each part very carefully
so that it can be reinstalled in its original place. 

EAS00239

CHECKING THE VALVES AND VALVE 
GUIDES

The following procedure applies to all of the
valves and valve guides. 
1. Measure: 

• valve-stem-to-valve-guide clearance

Out of specification 

 Replace the valve

guide.

Valve-stem-to-valve-guide clearance = 

Valve guide inside diameter 

a

 - 

Valve stem diameter 

b

Valve-stem-to-valve-guide 
clearance 

Intake 

0.010 ~ 0.037 mm 
(0.0004 ~ 0.0015 in) 
<Limit>: 0.08 mm (0.0031 in) 

Exhaust 

0.025 ~ 0.052 mm 
(0.0010 ~ 0.0020 in) 
<Limit>: 0.1 mm (0.0039 in)

5 - 42

ENG

VALVES AND VALVE SPRINGS

2. Replace: 

• valve guide

NOTE:

To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven. 

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a. Remove the valve guide with the valve

guide remover 

1

b. Install the new valve guide with the valve

guide installer 

2

 and valve guide remover

1

c. After installing the valve guide, bore the

valve guide with the valve guide reamer 

3

to obtain the proper valve-stem-to-valve-
guide clearance.

NOTE:

After replacing the valve guide, reface the
valve seat. 

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Valve guide remover (ø6) 

YM-04064-A

Valve guide installer (ø6) 

YM-04065-A

Valve guide reamer (ø6) 

YM-04066

3. Eliminate: 

• carbon deposits 

(from the valve face and valve seat)

4. Check: 

• valve face 

Pitting/wear 

 Grind the valve face. 

• valve stem end 

Mushroom shape or diameter larger than
the body of the valve stem 

 Replace the

valve.

5 - 43

ENG

VALVES AND VALVE SPRINGS

5. Measure: 

• valve margin thickness 

a

 

Out of specification 

 Replace the valve.

Valve margin thickness 

0.7 ~ 1.3 mm (0.0276 ~ 0.0512 in)

6. Measure: 

• valve stem runout 

Out of specification 

 Replace the valve.

NOTE:

• When installing a new valve, always replace

the valve guide. 

• If the valve is removed or replaced, always

replace the oil seal. 

Valve stem runout 

0.01 mm (0.0004 in)

EAS00240

CHECKING THE VALVE SEATS

The following procedure applies to all of the
valves and valve seats. 
1. Eliminate: 

• carbon deposits 

(from the valve face and valve seat)

2. Check: 

• valve seat 

Pitting/wear 

 Replace the cylinder head.

5 - 44

ENG

VALVES AND VALVE SPRINGS

3. Measure: 

• valve seat width 

a

 

Out of specification 

 Replace the cylinder

head.

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a. Apply Mechanic’s blueing dye (Dykem) 

b

onto the valve face. 

b. Install the valve into the cylinder head. 
c. Press the valve through the valve guide and

onto the valve seat to make a clear impres-
sion. 

d. Measure the valve seat width.

NOTE:

Where the valve seat and valve face contacted
one another, the blueing will have been
removed. 

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Valve seat width 

Intake

0.9 ~ 1.1 mm 
(0.0354 ~ 0.0433 in) 

Exhaust 

0.9 ~ 1.1 mm 
(0.0354 ~ 0.0433 in) 

5 - 45

ENG

VALVES AND VALVE SPRINGS

4. Lap: 

• valve face 
• valve seat

NOTE:

After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped. 

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a. Apply a coarse lapping compound 

a

 to the

valve face.

CAUTION:

Do not let the lapping compound enter the
gap between the valve stem and the valve
guide. 

b. Apply molybdenum disulfide oil onto the

valve stem. 

c. Install the valve into the cylinder head. 
d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all
of the lapping compound.

NOTE:

For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands. 

e. Apply a fine lapping compound to the valve

face and repeat the above steps. 

f. After every lapping procedure, be sure to

clean off all of the lapping compound from
the valve face and valve seat. 

g. Apply Mechanic’s blueing dye (Dykem) 

b

onto the valve face. 

h. Install the valve into the cylinder head. 
i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-
sion. 

j. Measure the valve seat width again. If the

valve seat width is out of specification,
reface and lap the valve seat. 

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5 - 46

ENG

VALVES AND VALVE SPRINGS

EAS00241

CHECKING THE VALVE SPRINGS

The following procedure applies to all of the
valve springs. 
1. Measure: 

• valve spring free length 

a

 

Out of specification 

 Replace the valve

spring.

Valve spring free length 

Intake valve spring 

38.26 mm (1.51 in) 
<Limit>: 36.26 mm (1.43 in)

Exhaust valve spring 

38.26 mm (1.51 in) 
<Limit>: 36.26 mm (1.43 in)

2. Measure: 

• compressed valve spring force 

a

 

Out of specification 

 Replace the valve

spring.

b

Installed length

3. Measure: 

• valve spring tilt 

a

 

Out of specification 

 Replace the valve

spring.

Compressed valve spring force 
(installed) 

Intake and exhaust inner valve
spring 

6.3 ~ 7.3 kg at 29.0 mm 
(13.9 ~ 16.1 lb at 1.14 in) 

Intake and exhaust outer valve
spring 

13.9 ~ 16.1 kg at 31.0 mm 
(30.6 ~ 35.5 lb at 1.22 in)

Spring tilt limit 

Intake and exhaust inner valve
spring 

2.4 mm (0.094 in) 

Intake and exhaust outer valve
spring 

2.4 mm (0.094 in) 

5 - 47

ENG

VALVES AND VALVE SPRINGS

EAS00246

INSTALLING THE VALVES

The following procedure applies to all of the
valves and related components.
1. Deburr: 

• valve stem end 

(with an oil stone)

2. Lubricate: 

• valve stem 

1

 

• oil seal 

2

 

(with the recommended lubricant)

Recommended lubricant 

Molybdenum disulfide oil

3. Install: 

• lower spring seat 

1

 

• valve stem seal 

2

 

• valve 

3

 

• inner valve spring 

4

 

• outer valve spring 

5

 

• upper spring seat 

6

 

(into the cylinder head)

NOTE:

Install the valve springs with the larger pitch 

a

facing up. 

b

Smaller pitch

5 - 48

ENG

VALVES AND VALVE SPRINGS

4. Install: 

• valve cotters 

1

NOTE:

Install the valve cotters by compressing the
valve springs with the valve spring compressor
set 

1

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.

CAUTION:

Hitting the valve tip with excessive force
could damage the valve. 

Valve spring compressor set

YM-04019

6. Install: 

• cylinder head

Refer to “CYLINDER HEADS”.

5 - 49

ENG

CYLINDERS AND PISTONS

EAS00252

CYLINDERS AND PISTONS

1

3

4

5

7

8

9

10

3

4

6

5

5

7

6

5

8

9

10

2

New

New

New

New

New

New

E

E

E

Order

Job/Part

Q’ty

Remarks

Removing the cylinders and pistons

Remove the parts in the order listed.

Cylinder heads

Refer to “CYLINDER HEADS”.

1

Front cylinder

1

Refer to “INSTALL-
ING THE PIS-
TONS AND 
CYLINDERS”.

2

Rear cylinder 

1

3

Cylinder gasket

2

4

Dowel pin

4

Refer to “REMOV-
ING THE CYLIN-
DERS AND 
PISTONS”.

5

Piston pin clip

4

6

Piston pin

2

7

Piston

2

8

Top ring

2

9

2nd ring

2

10

Oil ring

2

For installation, reverse the removal 
procedure.

5 - 50

ENG

CYLINDERS AND PISTONS

EAS00254

REMOVING THE CYLINDERS AND 
PISTONS

The following procedure applies to all of the
cylinders and pistons. 
1. Remove: 

• piston pin clips 

1

 

• piston pin 

2

 

• piston 

3

CAUTION:

Do not use a hammer to drive the piston
pin out. 

NOTE:

• Before removing the piston pin clip, cover the

crankcase opening with a clean rag to pre-
vent the piston pin clip from falling into the
crankcase. 

• For reference during installation, put an iden-

tification mark on each piston crown. 

• Before removing the piston pin, deburr the

piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and the
piston pin is still difficult to remove, remove it
with the piston pin puller 

4

Piston pin puller 

YU-01304

2. Remove: 

• top ring 
• 2nd ring 
• oil ring

NOTE:

When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown. 

5 - 51

ENG

CYLINDERS AND PISTONS

EAS00258

CHECKING THE CYLINDERS AND 
PISTONS

The following procedure applies to all of the
cylinders and pistons.
1. Check: 

• piston wall 
• cylinder wall 

Vertical scratches 

 Replace the cylinder,

and the piston and piston rings as a set.

2. Measure: 

• piston-to-cylinder clearance 

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a. Measure cylinder bore “C” with the cylinder

bore gauge.

NOTE:

Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the
cylinder. Then, find the average of the mea-
surements. 

b. If out of specification, replace the cylinder,

and the piston and piston rings as a set. 

c. Measure piston skirt diameter “P” with the

micrometer.

a

5 mm (0.20 in) from the bottom edge of the pis-
ton

Cylinder bore gauge 
(50 ~ 100 mm)

YU-03017

Cylinder bore “C” 

97.000 ~ 97.010 mm 

(3.8189 ~ 3.8193 in) 

Taper limit “T” 

0.05 mm (0.0016 in)

Out of round “R” 

0.05 mm (0.0016 in)

“C” = maximum of D

1

 ~ D

6

 

“T” = maximum of D

1

 or D

2

 - maximum of 

D

5

 or D

6

 

“R” = maximum of D

1

, D

3

 or D

5

 - minimum 

of D

2

, D

4

 or D

6

Micrometer (75 ~ 100 mm)

YU-03009

5 - 52

ENG

CYLINDERS AND PISTONS

d. If out of specification, replace the piston and

piston rings as a set. 

e. Calculate the piston-to-cylinder clearance

with the following formula.

f. If out of specification, replace the cylinder,

and the piston and piston rings as a set. 

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Piston size “P” 

Standard

96.960 ~ 96.975 mm 

(3.8173 ~ 3.8179 in) 

Piston-to-cylinder clearance = 

Cylinder bore “C” - 
Piston skirt diameter “P”

Piston-to-cylinder clearance 

0.025 ~ 0.050 mm 
(0.001 ~ 0.002 in) 
<Limit>: 0.15 mm (0.006 in)

EAS00263

CHECKING THE PISTON RINGS

1. Measure: 

• piston ring side clearance 

Out of specification 

 Replace the piston

and piston rings as a set.

NOTE:

Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings. 

Piston ring side clearance 

Top ring 

0.03 ~ 0.08 mm 
(0.0012 ~ 0.0031 in) 
<Limit>: 0.12 mm (0.0047 in) 

2nd ring 

0.03 ~ 0.07 mm 
(0.0012 ~ 0.0028 in) 
<Limit>: 0.12 mm (0.0047 in)

5 - 53

ENG

CYLINDERS AND PISTONS

2. Install: 

• piston ring 

(into the cylinder)

NOTE:

Level the piston ring into the cylinder with the
piston crown. 

a

10 mm (0.39 in)

3. Measure: 

• piston ring end gap 

Out of specification 

 Replace the piston

ring.

NOTE:

The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings. 

Piston ring end gap 

Top ring 

0.30 ~ 0.45 mm 
(0.012 ~ 0.018 in) 
<Limit>: 0.65 mm (0.026 in) 

2nd ring 

0.30 ~ 0.45 mm 
(0.012 ~ 0.018 in) 
<Limit>: 0.80 mm (0.031 in) 

Oil ring 

0.2 ~ 0.7 mm 
(0.008 ~ 0.028 in)

EAS00266

CHECKING THE PISTON PINS

The following procedure applies to all of the
piston pins.
1. Check: 

• piston pin 

Blue discoloration/grooves 

 Replace the

piston pin and then check the lubrication
system.

2. Measure: 

• piston pin outside diameter 

a

 

Out of specification 

 Replace the piston

pin.

Piston pin outside diameter 

21.991 ~ 22.000 mm 
(0.8658 ~ 0.8661 in)
<Limit>: 21.971 mm (0.8650 in) 

 

 

 

 

 

 

 

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