Yamaha XV1700P, XV1700PC. Service Manual - part 21

5 - 54

ENG

CYLINDERS AND PISTONS

3. Measure: 

• piston pin bore diameter (in the piston) 

b

 

Out of specification 

→

 Replace the piston

pin.

4. Calculate: 

• piston-pin-to-piston-pin-bore clearance 

Out of specification 

→

 Replace the piston

pin and piston as a set.

Piston pin bore diameter (in the 
piston)

22.004 ~ 22.015 mm 
(0.8663 ~ 0.8667 in)
<Limit>: 22.045 mm (0.8679 in) 

Piston-pin-to-piston clearance = 

Piston pin bore diameter (in the piston)

b

 - Piston pin outside diameter 

a

Piston-pin-to-piston pin bore 
clearance 

0.004 ~ 0.024 mm 
(0.00016 ~ 0.00094 in) 
<Limit>: 0.074 mm (0.0029 in)

EAS00268

INSTALLING THE PISTONS AND 
CYLINDERS

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

• top ring 
• 2nd ring 
• oil ring 

NOTE:

_ 

Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up. 

5 - 55

ENG

CYLINDERS AND PISTONS

2. Install: 

• piston 

1

 

• piston pin 

2

 

• piston pin clips 

3

NOTE:

_ 

• Apply engine oil onto the piston pin. 
• Make sure the “arrow” mark 

a

 on the piston

faces towards the front of the motorcycle. 

• Before installing the piston pin clip, cover the

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

3. Install: 

• dowel pins 

1

• cylinder gasket 

2

 

4. Lubricate: 

• piston 
• piston rings 
• cylinder 

(with the recommended lubricant)

Recommended lubricant 

Engine oil

New

1

2

1

New

New

5. Offset: 

• piston ring end gaps

a

Top ring 

b

Lower oil ring rail 

c

Upper oil ring rail 

d

2nd ring 

È

Forward

6. Install: 

• cylinder 

1

NOTE:

_ 

While compressing the piston rings with one
hand, install the cylinder with the other hand. 

1

5 - 56

ENG

CLUTCH

EAS00273

CLUTCH

CLUTCH COVER

4

9

2

3

5

6

7

8

9

(5)

(7)

(4)

1

T

 

R

.

.

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

.

.

12 Nm (1.2 m 

•

 

kg, 8.7 ft

 

•

 

Ib)

New

Order

Job/Part

Q’ty

Remarks

Removing the clutch cover

Remove the parts in the order listed.

Left side cover

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

Sub fuel tank

Refer to “SUB FUEL TANK”.

Engine left side cover

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

Engine oil

Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.

1

Clutch cable

1

Disconnect.

Refer to “INSTALLING THE 
CLUTCH”.

2

Pull lever

1

3

Pull lever spring

1

4

Crankshaft position sensor lead

1

Disconnect.

5 - 57

ENG

CLUTCH

4

9

2

3

5

6

7

8

9

(5)

(7)

(4)

1

T

 

R

.

.

10 Nm (1.0 m 

•

 

kg, 7.2 ft

 

•

 

Ib)

T

 

R

.

.

12 Nm (1.2 m 

•

 

kg, 8.7 ft

 

•

 

Ib)

New

Order

Job/Part

Q’ty

Remarks

5

Shift arm

1

Refer to “INSTALL-
ING THE CLUTCH”.

6

Clutch cable holder

1

Refer to “REMOV-
ING THE CLUTCH”.

7

Clutch  cover

1

8

Clutch cover gasket

1

9

Dowel pin

1

For installation, reverse the removal 
procedure.

5 - 58

ENG

CLUTCH

2

3

4

4

3

5

5

5

6

1

LT

LT

LT

LT

LT

T

 

R

.

.

7 Nm (0.7 m

 

•

 kg, 5.1 ft 

•

 Ib)

LS

LS

Order

Job/Part

Q’ty

Remarks

Removing the pull lever shaft and 
crankshaft position sensor

Remove the parts in the order listed.

Pull lever

1

Pull lever spring

1

1

Circlip

1

2

Pull lever shaft

1

3

Oil  seal

2

4

Bearing

3

5

Crankshaft position sensor lead holder

3

Refer to “INSTALLING THE CRANK-
SHAFT POSITION SENSOR AND PULL 
LEVER SHAFT”.

6

Crankshaft position sensor

1

For installation, reverse the removal 
procedure.

5 - 59

ENG

CLUTCH

EAS00274

CLUTCH

8

7

6

18 19

20

17

16

15

14

13

9 12

11

10

1

2

3

4

5

21

22

23

24

E

E

LT

T

 

R

.

.

100 Nm (10.0 m 

•

 kg, 72 ft 

•

 lb)

T

 

R

.

.

80 Nm (8.0 m 

•

 

kg, 58 ft

 

•

 

Ib)

T

 

R

.

.

8 Nm (0.8 m

 

•

 kg, 5.8 ft 

•

 Ib)

New

New

(6)

8

9

9

Order

Job/Part

Q’ty

Remarks

Removing the clutch

Remove the parts in the order listed. 

Generator cover

Refer  to  “GENERATOR AND STARTER
CLUTCH”. 

1

Clutch spring plate retainer

1

Refer to “INSTALL-
ING THE CLUTCH”.

2

Clutch spring plate

1

3

Clutch spring plate seat

1

4

Pressure plate

1

5

Pull rod

1

6

Friction plate 2

6

Green painting

7

Clutch plate

7

8

Cushion spring

2

9

Friction plate 1

3

Black painting

10

Lock washer

1

Refer to “REMOV-
ING THE CLUTCH”.

11

Wire circlip

1

12

Clutch plate

1

5 - 60

ENG

CLUTCH

8

7

6

18 19

20

17

16

15

14

13

9 12

11

10

1

2

3

4

5

21

22

23

24

E

E

LT

T

 

R

.

.

100 Nm (10.0 m 

•

 kg, 72 ft 

•

 lb)

T

 

R

.

.

80 Nm (8.0 m 

•

 

kg, 58 ft

 

•

 

Ib)

T

 

R

.

.

8 Nm (0.8 m

 

•

 kg, 5.8 ft 

•

 Ib)

New

New

(6)

8

9

9

Order

Job/Part

Q’ty

Remarks

13

Clutch damper spring

1

Refer to “REMOV-
ING THE CLUTCH”.

Refer to “INSTALL-
ING THE CLUTCH”.

14

Clutch damper spring seat

1

15

Clutch boss

1

16

Thrust washer

1

17

Clutch housing

1

18

Circlip

1

19

Oil pump drive gear

1

20

Dowel pin

1

21

Spacer

1

22

Crankshaft position sensor rotor

1

Refer to “REMOV-
ING THE PRIMARY 
DRIVE GEAR”.

23

Primary drive gear

1

24

Straight key

1

For installation, reverse the removal 
procedure.

5 - 61

ENG

CLUTCH

EAS00277

REMOVING THE CLUTCH

1. Remove: 

• clutch cable holder 

1

• clutch cover 

2

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. 

2. Straighten the lock washer tab. 
3. Loosen: 

• clutch boss nut 

1

NOTE:

_ 

While holding the clutch boss 

2

 with the uni-

versal clutch holder 

3

, loosen the clutch boss

nut. 

Universal clutch holder 

YM-91042

4. Remove: 

• clutch boss nut 

1

 

• lock washer 

2

 

• clutch boss assembly 

3

 

NOTE:

_ 

There is a built-in damper between the clutch
boss and the clutch plate. It is not necessary to
remove the wire circlip 

4

 and disassemble the

built-in damper unless there is serious clutch
chattering. 

5 - 62

ENG

CLUTCH

EAS00279

REMOVING THE PRIMARY DRIVE GEAR

1. Remove: 

• crankshaft position sensor rotor bolt 

1

 

NOTE:

_ 

While holding the generator rotor 

2

 with the

sheave holder 

3

, loosen the crankshaft posi-

tion sensor rotor bolt. 

Primary sheave holder 

YS-01880-A

EAS00280

CHECKING THE FRICTION PLATES

The following procedure applies to all of the
friction plates.
1. Check: 

• friction plate 

Damage/wear 

→

 Replace the friction plates

as a set.

2. Measure: 

• friction plate thickness 

Out of specification 

→

 Replace the friction

plates as a set.

NOTE:

_ 

Measure the friction plate at four places. 

Friction plate thickness 

2.9 ~ 3.1 mm (0.114 ~ 0.122 in)

EAS00281

CHECKING THE CLUTCH PLATES

The following procedure applies to all of the
clutch plates.
1. Check: 

• clutch plate 

Damage 

→

 Replace the clutch plates as a

set.

5 - 63

ENG

CLUTCH

2. Measure: 

• clutch plate warpage 

(with a surface plate and thickness gauge

1

) 

Out of specification 

→

 Replace the clutch

plates as a set.

Clutch plate warpage limit 

0.2 mm (0.008 in)

EAS00283

CHECKING THE CLUTCH PLATE SPRING

1. Check: 

• clutch plate spring 

1

 

Damage 

→

 Replace.

2. Check: 

• clutch plate spring seat 

2

 

Damage 

→

 Replace.

EAS00284

CHECKING THE CLUTCH HOUSING

1. Check: 

• clutch housing dogs 

Damage/pitting/wear 

→

 Deburr the clutch

housing dogs or replace the clutch housing.

NOTE:

_ 

Pitting on the clutch housing dogs will cause
erratic clutch operation. 

2. Check: 

• bearing 

Damage/wear 

→

 Replace the bearing and

clutch housing.

EAS00285

CHECKING THE CLUTCH BOSS

1. Check: 

• clutch boss splines 

Damage/pitting/wear 

→

 Replace the clutch

boss.

NOTE:

_ 

Pitting on the clutch boss splines will cause
erratic clutch operation. 

5 - 64

ENG

CLUTCH

EAS00286

CHECKING THE PRESSURE PLATE

1. Check: 

• pressure plate 

1

 

Cracks/damage 

→

 Replace. 

• bearing 

2

 

Damage/wear 

→

 Replace.

EAS00287

CHECKING THE PULL LEVER SHAFT AND 
PULL ROD

1. Check: 

• pull lever shaft pinion gear teeth 

a

 

• pull rod teeth 

b

 

Damage/wear 

→

 Replace the pull rod and

pull lever shaft pinion gear as a set.

2. Check: 

• pull rod bearing 

Damage/wear 

→

 Replace.

EAS00292

CHECKING THE PRIMARY DRIVE

1. Check: 

• primary drive gear 

1

 

• primary driven gear 

2

 

Damage/wear 

→

 Replace the primary drive

gear and clutch housing as a set. 
Excessive noise during operation 

→

Replace the primary drive gear and clutch
housing as a set. 

INSTALLING THE CRANKSHAFT POSITION 
SENSOR AND PULL LEVER SHAFT

1. Apply: 

• sealant 

(onto the crankshaft position sensor lead
grommet)

Quick Gasket

®

 

ACC-11001-05-01

5 - 65

ENG

CLUTCH

2. Install: 

• crankshaft position sensor 

• crankshaft position sensor lead holder

NOTE:

_ 

Apply locking agent (LOCTITE

®

) to the

threads of the crankshaft position sensor bolts
and crankshaft position sensor lead holder
bolts. 

T

 

R

.

.

7 Nm (0.7 m  •  kg, 5.1 ft  •  lb)

T

 

R

.

.

7 Nm (0.7 m  •  kg, 5.1 ft  •  lb)

EAS00303

INSTALLING THE PRIMARY DRIVE GEAR

1. Install: 

• straight key 

1

 

• primary drive gear 

2

 

• crankshaft position sensor rotor 

3

 

• spacer 

4

 

• crankshaft position sensor rotor bolt 

5

 

CAUTION:

The timing marks on the crankshaft posi-
tion sensor rotor must face outside.

NOTE:

_ 

While holding the generator rotor 

6

 with the

primary sheave holder 

7

, tighten the crank-

shaft position sensor rotor bolt. 

2. Bend the lock washer tab along a flat side of

the nut.

Primary sheave holder 

YS-01880-A

T

 

R

.

.

100 Nm (10.0 m  •  kg, 72 ft  •  lb)

5 - 66

ENG

CLUTCH

EAS00293

INSTALLING THE CLUTCH

1. Install: 

• dowel pin 

1

 

• oil pump drive gear 

2

 

• plate 

3

 

• circlip 

4

 

2. Install: 

• clutch housing 

1

 

• thrust washer 

2

NOTE:

_ 

• Lubricate the clutch housing bearings with

engine oil.

• Make sure that the primary driven gear teeth

and primary drive gear teeth mesh correctly.

• Make sure that the oil pump drive gear teeth

and oil pump driven gear teeth mesh cor-
rectly. 

3. Install: 

• clutch boss assembly 

1

 

NOTE:

_ 

• If the wire circlip 

2

 has been removed, care-

fully install a new one.

• Install the clutch damper spring 

3

 with the

“OUTSIDE” mark facing out. 

5 - 67

ENG

CLUTCH

4. Install: 

• clutch boss 

1

 

• lock washer 

 

• clutch boss nut 

2

NOTE:

_ 

While holding the clutch boss with the univer-
sal clutch holder 

3

, tighten the clutch boss

nut. 

5. Bend the lock washer tab along a flat side of

the nut. 

Universal clutch holder 

YM-91042

New

T

 

R

.

.

80 Nm (8.0 m  •  kg, 58 ft  •  lb)

6. Lubricate: 

• friction plates 
• clutch plates 

(with the recommended lubricant)

Recommended lubricant 

Engine oil

7. Install: 

• friction plates 
• clutch plates
• cushion springs

NOTE:

_ 

• First, install a friction plate and then alternate

between a clutch plate and a friction plate. 

• Apply molybdenum disulfide grease onto the

bearing and pull rod teeth. 

• Align the two embossed mark 

a

 on the

clutch housing with the two semicircular slots

b

 in the friction plates.

5 - 68

ENG

CLUTCH

8. Install: 

• pressure plate 

1

 

NOTE:

_ 

Align the punch mark 

a

 in the pressure plate

with the punch mark 

b

 in the clutch boss. 

9. Install: 

• clutch spring plate seat 

1

 

• clutch spring plate 

2

 

• clutch spring plate retainer 

3

 

NOTE:

_ 

Tighten the clutch spring plate retainer bolts in
stages and in a crisscross pattern. 

1

2

3

T

 

R

.

.

8 Nm (0.8 m  •  kg, 5.8 ft  •  lb)

10.Install: 

• dowel pins 

1

 

• clutch cover gasket 

2

New

11.Install: 

• clutch cover 

1

 

• clutch cable holder 

2

 

NOTE:

_ 

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

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

12.Connect: 

• crankshaft position sensor coupler

NOTE:

_ 

Refer to “CABLE ROUTING” in chapter 2. 

5 - 69

ENG

CLUTCH

13.Install: 

• shift arm 

1

 

NOTE:

_ 

Align the mark 

a

 in the shift shaft with the slot

in the shift arm. 

T

 

R

.

.

12 Nm (1.2 m  •  kg, 8.7 ft  •  lb)

14.Install: 

• pull lever spring 
• pull lever 

NOTE:

_ 

If there is no free play in the clutch, install the
pull lever to the pull lever shaft in order to get
the distance 

a

 between the pull lever and

clutch cable holder to 31.3 mm (1.23 in). 

T

 

R

.

.

12 Nm (1.2 m  •  kg, 8.7 ft  •  lb)

15.Connect: 

• clutch cable 

1

 

16.Adjust: 

• clutch cable free play

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