Yamaha XV1700P, XV1700PC. Service Manual - part 22

 

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Yamaha XV1700P, XV1700PC. Service Manual - part 22

 

 

5 - 70

ENG

SHIFT SHAFT AND STOPPER LEVER

EAS00327

SHIFT SHAFT AND STOPPER LEVER

5

4

6

7

2

3

1

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

22 Nm (2.2 m 

 

kg, 16 ft

 

 

Ib)

LT

LT

LS

Order

Job/Part

Q’ty

Remarks

Removing the shift shaft and 
stopper lever 

Remove the parts in the order listed. 

Engine oil

Drain.

Clutch housing

Refer to “CLUTCH”.

1

Shift shaft

1

Refer to “INSTALLING THE STOPPER 
LEVER AND SHIFT SHAFT”.

2

Circlip

2

3

Shift shaft spring

1

4

Shift shaft spring stopper

1

5

Washer

1

6

Stopper lever

1

7

Stopper lever spring

1

For installation, reverse the removal 
procedure.

5 - 71

ENG

SHIFT SHAFT AND STOPPER LEVER

EAS00328

CHECKING THE SHIFT SHAFT

1. Check: 

• shift shaft 

1

 

• shift lever spring 

2

 

Damage/wear 

 Replace.

EAS00330

CHECKING THE STOPPER LEVER

1. Check: 

• stopper lever 

1

 

Bends/damage 

 Replace.

Roller turns roughly 

 Replace the stopper

lever.

EAS00331

INSTALLING THE STOPPER LEVER AND 
SHIFT SHAFT

1. Install: 

• stopper lever 

1

 

• stopper lever spring 

2

 

NOTE:

• Apply locking agent (LOCTITE

®

) to the

threads of stopper lever bolt. 

• Hook the ends of the stopper lever spring

onto the stopper lever and the crankcase
boss 

3

• Mesh the stopper lever with the shift drum

segment assembly. 

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

2. Install: 

• washer
• shift shaft spring stopper 

1

 

NOTE:

Apply locking agent (LOCTITE

®

) to the

threads of shift shaft spring stopper. 

T

 

R

.

.

22 Nm (2.2 m  •  kg, 16 ft  •  lb)

5 - 72

ENG

SHIFT SHAFT AND STOPPER LEVER

3. Install: 

• shift shaft spring 
• circlips 
• shift shaft 

1

 

NOTE:

Install the end of the shift shaft spring onto the
shift shaft spring stopper 

2

5 - 73

ENG

GENERATOR AND STARTER CLUTCH

EAS00341

GENERATOR AND STARTER CLUTCH

STATOR COIL ASSEMBLY

2

1

2

6

1

3

4

5

1

12

10

9

8

7

11

(9)

LT

New

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

48 Nm (4.8 m 

 

kg, 35 ft

 

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

 kg, 5.1 ft 

 Ib)

Order

Job/Part

Q’ty

Remarks

Removing the stator coil assembly 

Remove the parts in the order listed. 

Muffler/exhaust pipes

Refer to “ENGINE”.

Engine oil

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

1

Plastic locking tie

3

2

Plastic band

2

3

Rear brake light switch coupler

1

Disconnect.

4

Horn 1 connectors

2

5

Rider footrest assembly (right)

1

6

Stator coil assembly coupler

1

Disconnect.

7

Oil delivery pipe

1

5 - 74

ENG

GENERATOR AND STARTER CLUTCH

2

1

2

6

1

3

4

5

1

12

10

9

8

7

11

(9)

LT

New

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

48 Nm (4.8 m 

 

kg, 35 ft

 

 

Ib)

T

 

R

.

.

7 Nm (0.7 m

 

 kg, 5.1 ft 

 Ib)

Order

Job/Part

Q’ty

Remarks

8

Generator cover

1

9

Generator cover gasket

1

10

Dowel pin

2

11

Stator coil assembly lead holder

1

12

Stator coil assembly

1

For installation, reverse the removal 
procedure.

5 - 75

ENG

GENERATOR AND STARTER CLUTCH

EAS00343

GENERATOR AND STARTER CLUTCH

Order

Job/Part

Q’ty

Remarks

Removing the generator rotor

Remove the parts in the order listed.

1

Starter clutch idle gear shaft #2

1

2

Starter clutch idle gear shaft #1

1

3

Starter clutch idle gear #2

1

4

Starter clutch idle gear #1

1

5

Generator rotor

1

6

Woodruff key

1

7

Starter clutch gear

1

For installation, reverse the removal 
procedure.

5 - 76

ENG

GENERATOR AND STARTER CLUTCH

EAS00347

REMOVING THE GENERATOR

1. Remove: 

• generator cover 

1

 

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. Remove: 

• generator rotor bolt 

1

 

• washer

NOTE:

While holding the generator rotor 

2

 with the

primary sheave holder 

3

, loosen the genera-

tor rotor bolt. 

Primary sheave holder 

YS-01880-A

3. Remove: 

• generator rotor 

1

 

(with the alternator rotor puller 

2

Alternator rotor puller

YM-01080-A

EAS00348

CHECKING THE STARTER CLUTCH

1. Check: 

• starter clutch idle gears 

1

 

• starter clutch gear 

2

 

Burrs/chips/roughness/wear 

 Replace the

defective part(s).

5 - 77

ENG

GENERATOR AND STARTER CLUTCH

2. Check: 

• starter clutch operation

▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼ ▼▼▼

▼▼▼

a. Install the starter clutch gear 

1

 onto the

starter clutch and hold the starter clutch. 

b. When turning the starter clutch gear clock-

wise 

È

, the starter clutch and the starter

clutch gear should engage, otherwise the
starter clutch is faulty and must be
replaced. 

c. When turning the starter clutch gear coun-

terclockwise 

É

, it should turn freely, other-

wise the starter clutch is faulty and must be
replaced. 

▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲ ▲▲▲

▲▲▲

EAS00354

INSTALLING THE GENERATOR

1. Install: 

• starter clutch gear 

1

 

• woodruff key 
• generator rotor 

2

 

• washer 
• generator rotor bolt 

3

 

NOTE:

• Clean the tapered portion of the crankshaft

and the generator rotor hub. 

• When installing the generator rotor, make

sure the woodruff key is properly seated in
the keyway of the crankshaft. 

2. Tighten: 

• generator rotor bolt 

1

NOTE:

While holding the generator rotor 

2

 with the

primary sheave holder 

3

, tighten the genera-

tor rotor bolt. 

Primary sheave holder 

YS-01880-A

T

 

R

.

.

130 Nm (13.0 m  •  kg, 94 ft  •  lb)

5 - 78

ENG

GENERATOR AND STARTER CLUTCH

3. Apply: 

• sealant

(onto the stator coil assembly lead grom-
met)

Quick Gasket

®

 

ACC-11001-05-01

4. Install: 

• stator coil assembly 

1

 

• stator coil assembly lead holder

NOTE:

Apply locking agent (LOCTITE

®

) to the

threads of the stator coil assembly bolts. 

T

 

R

.

.

7 Nm (0.7 m  •  kg, 5.2 ft  •  lb)

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

5. Connect: 

• stator coil assembly coupler
• horn 1 connectors
• rear brake light switch coupler 

1

 

NOTE:

Refer to “CABLE ROUTING” in chapter 2. 

5 - 79

ENG

TRANSFER GEAR CASE

TRANSFER GEAR CASE

2

1

4

4

9

3

5

6

4

4

7

11

10

12

8

13

(5)

New

New

New

LT

LT

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

8 Nm (0.8 m

 

 kg, 5.8 ft 

 Ib)

T

 

R

.

.

24 Nm (2.4 m 

 

kg, 17 ft

 

 

Ib)

T

 

R

.

.

18 Nm (1.8 m 

 

kg, 13 ft

 

 

Ib)

T

 

R

.

.

100 Nm (10.0 m 

 kg, 72 ft 

 lb)

T

 

R

.

.

30 Nm (3.0 m 

 

kg, 22 ft

 

 

Ib)

Order

Job/Part

Q’ty

Remarks

Removing the transfer gear case 
cover

Remove the parts in the order listed. 

Muffler/exhaust pipes

Refer to “ENGINE”. 

Engine oil

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

Transfer gear oil

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

Drive sprocket

Refer  to  “DRIVE BELT AND DRIVE
SPROCKET” in chapter 4.

1

Oil pipe #1

1

2

Oil pipe #2

1

3

Cover

1

5 - 80

ENG

TRANSFER GEAR CASE

2

1

4

4

9

3

5

6

4

4

7

11

10

12

8

13

(5)

New

New

New

LT

LT

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

8 Nm (0.8 m

 

 kg, 5.8 ft 

 Ib)

T

 

R

.

.

24 Nm (2.4 m 

 

kg, 17 ft

 

 

Ib)

T

 

R

.

.

18 Nm (1.8 m 

 

kg, 13 ft

 

 

Ib)

T

 

R

.

.

100 Nm (10.0 m 

 kg, 72 ft 

 lb)

T

 

R

.

.

30 Nm (3.0 m 

 

kg, 22 ft

 

 

Ib)

Order

Job/Part

Q’ty

Remarks

4

Dowel pin

4

5

Transfer gear oil pump

1

6

Transfer gear oil pump gasket

1

7

Transfer gear case cover

1

8

Transfer gear case cover gasket

1

9

Oil strainer

1

10

Lock washer

1

11

Primary chain

1

12

Middle drive gear

1

13

Middle driven shaft

1

For installation, reverse the removal 
procedure.

5 - 81

ENG

TRANSFER GEAR CASE

Order

Job/Part

Q’ty

Remarks

Disassembling the transfer gear 
case oil pump

Remove the parts in the order listed. 

1

 

Oil pump cover

1

2

 Pin

2

3

 Pin

1

4

 

Oil pump shaft

1

5

 

Oil pump inner rotor

1

6

 

Oil pump outer rotor

1

7

 

Oil pump housing

1

For assembly, reverse the disassembly 
procedure.

5 - 82

ENG

FUEL PUMP

(6)

9

4

8

7

6

5

10

1

2

3

4

T

 

R

.

.

5 Nm (0.5 m

 

 kg, 3.6 ft 

 Ib)

New

New

Order

Job/Part

Q’ty

Remarks

Removing the fuel pump

Remove the parts in the order listed.

Seat/cover

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

Fuel tank

Refer to “FUEL TANK” in chapter 3.

1

Throttle stop screw bracket

1

2

Fuel hose joint bracket

1

3

Fuel hose joint

1

4

Fuel hose

2

5

Fuel inlet hose

1

6

Hose holder

1

7

Fuel outlet hose 

1

8

Fuel pump coupler

1

Disconnect.

9

Fuel pump cover

1

10

Fuel pump

1

For installation, reverse the removal 
procedure.

TRANSFER GEAR CASE

5 - 83

ENG

REMOVING THE FUEL PUMP

1. Remove:

• fuel pump

CAUTION:

• Do not drop the fuel pump or give it a

strong shock.

• Do not touch the base section of the fuel

sender.

INSTALL THE FUEL PUMP

1. Install:

• fuel pump 

NOTE:

• Do not damage the installation surfaces of

the fuel tank when installing the fuel pump.

• Always use a new fuel pump gasket.
• Install the fuel pump as shown in the illustra-

tion.

• Tighten the fuel pump bolts in the proper

tightening sequence as shown.

T

 

R

.

.

5 Nm (0.5 m  •  kg, 3.6 ft  •  lb)

TRANSFER GEAR CASE

5 - 84

ENG

SUB FUEL TANK

4

2

3

5

7

6

8

9

1

T

 

R

.

.

10 Nm (1.0 m 

 

kg, 7.2 ft

 

 

Ib)

T

 

R

.

.

28 Nm (2.8 m 

 

kg, 20 ft

 

 

Ib)

Order

Job/Part

Q’ty

Remarks

Removing the sub fuel tank

Remove the parts in the order listed.

Fuel pump

Refer to “FUEL PUMP”.

Battery

Refer to “BATTERY” in chapter 3.

1

Battery negative lead

1

2

Starter motor lead

1

3

Battery positive lead

1

Disconnect.

4

Starter relay coupler

1

Disconnect.

5

Relay assembly

1

6

Plastic locking tie

1

7

Battery box

1

8

Sub fuel tank bracket

1

9

Sub fuel tank

1

For installation, reverse the removal 
procedure.

TRANSFER GEAR CASE

5 - 85

ENG

TRANSFER GEAR CASE

3

4

5

13

12

10

(4)

(4)

11

11

2

1

12

9

8

7

6

(5)

T

 

R

.

.

30 Nm (3.0 m 

 

kg, 22 ft

 

 

Ib)

T

 

R

.

.

50 Nm (5.0 m 

 

kg, 36 ft

 

 

Ib)

New

Order

Job/Part

Q’ty

Remarks

Removing the transfer gear case 

Remove the parts in the order listed. 

Seat/right side cover

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

1

Oil tank breather hose

1

2

Oil temperature sensor coupler

1

Disconnect.

3

Oil tank cover

1

4

Dipstick

1

5

Dipstick joint

1

6

Drive sprocket case

1

7

Dowel pin

2

8

Spacer

1

 

 

 

 

 

 

 

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