Yamaha XV1700P, XV1700PC. Service Manual - part 23

5 - 86

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

9

Oil  seal

1

10

Transfer gear case

1

11

Dowel pin

2

12

Bearing

2

13

Bearing housing

1

For installation, reverse the removal 
procedure.

5 - 87

ENG

TRANSFER GEAR CASE

6 8

7

3

2

5

1

9

8

(7)

(9)

4

4

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)

0

New

New

Order

Job/Part

Q’ty

Remarks

Disassembling the oil tank 

Remove the parts in the order listed. 

1

 

Oil temperature sensor 

1

2

 

Oil tank left cover

1

3

 

Oil tank left cover gasket

1

4

 Dowel 

pin

2

5

 Oil 

strainer

1

6

 

Oil tank right cover

1

7

 

Oil tank right cover gasket

1

8

 Dowel 

pin

2

9

 Oil 

pipe

1

0

 Oil 

tank

1

For assembly, reverse the disassembly 
procedure.

5 - 88

ENG

TRANSFER GEAR CASE

REMOVING THE MIDDLE DRIVEN SHAFT

NOTE:

_ 

Loosen the middle drive gear nut before
remove the drive sprocket. 

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

• middle drive gear nut 

1

 

NOTE:

_ 

When loosening the middle drive gear nut,
press down on the brake pedal so the middle
drive gear does not move. 

3. Remove: 

• primary chain 

1

 

• middle drive gear 

2

 

• middle driven shaft 

3

 

NOTE:

Remove the primary chain, middle drive gear
and middle driven shaft at the same time. 

CHECKING THE MIDDLE DRIVE

1. Check: 

• middle drive gear 

1

 

• middle driven gear 

2

 

Damage/wear 

→

 Replace the middle drive

gear, middle driven shaft and primary chain
as a set.

2. Check: 

• primary chain 

1

 

Damage/stiffness 

→

 Replace the primary

chain, middle drive gear and middle driven
shaft as a set.

5 - 89

ENG

TRANSFER GEAR CASE

CHECKING THE OIL STRAINER

1. Check: 

• oil strainer

Damage 

→

 Replace.

Contaminants 

→

 Clean with engine oil.

CHECKING THE OIL PUMP

1. Check: 

• oil pump housing 

1

 

• oil pump cover 

2

 

Cracks/damage/wear 

→

 Replace the defec-

tive part(-s).

2. Measure: 

• inner rotor-to-outer rotor tip clearance 

a

 

• outer rotor-to-oil pump housing clearance

b

 

Out of specification 

→

 Replace the oil

pump.

1

Inner rotor

2

Outer rotor

3

Oil pump housing

Inner rotor-to-outer rotor tip 
clearance 

0.07 ~ 0.12 mm 
(0.0028 ~ 0.0047 in)

Outer rotor-to-oil pump housing 
clearance 

0.03 ~ 0.08 mm 
(0.0012 ~ 0.0031 in)

3. Check: 

• oil pump operation 

Unsmooth 

→

 Repair or replace the defec-

tive part(-s).

5 - 90

ENG

TRANSFER GEAR CASE

CHECKING THE OIL PIPE

1. Check: 

• oil pipe 

Damage 

→

 Replace.

EAS00375

ASSEMBLING THE OIL PUMP

1. Lubricate: 

• inner rotor 
• outer rotor 
• oil pump shaft 

(with the recommended lubricant)

Recommended lubricant 

Engine oil

2. Install: 

• oil pump housing 

1

 

• oil pump outer rotor 

2

 

• oil pump inner rotor 

3

 

• oil pump shaft 

4

 

• pin 

5

 

NOTE:

_ 

• When installing the oil pump shaft, align the

pin in the oil pump shaft with the groove in
the oil pump inner rotor.

• Align the arrow 

a

 on the pump outer rotor

with the arrow 

b

 on the oil pump inner rotor. 

3. Install: 

• pins 

1

 

• oil pump cover 

2

 

NOTE:

_ 

Apply locking agent (LOCTITE

®

) to the

threads of the oil pump cover screws. 

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

5 - 91

ENG

TRANSFER GEAR CASE

4. Check: 

• oil pump operation 

Refer to “CHECKING THE OIL PUMP”.

INSTALLING THE TRANSFER GEAR CASE

1. Install: 

• middle driven shaft 

1

 

• middle drive gear 

2

 

• primary chain 

3

 

(into the transfer gear case)

• drive sprocket nut 

4

 

NOTE:

_ 

• Install the middle driven shaft, middle drive

gear and primary chain at the same time.

• Align the splines on the middle gear with the

splines on the drive axle.

• Temporarily install the drive sprocket nut

onto the middle driven shaft.

2

3

1

2. Install: 

• oil strainer 

1

 

• dowel pins 

2

 

• transfer gear case cover gasket 

3

2

New

2

3

1

New

3. Install: 

• transfer gear case cover 

1

 

• nut 

2

 

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

T

 

R

.

.

30 Nm (3.0 m  •  kg, 22 ft  •  lb)

5 - 92

ENG

TRANSFER GEAR CASE

4. Install: 

• lock washer
• middle drive gear nut 

1

 

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

the nut.

New

T

 

R

.

.

100 Nm (10.0 m  •  kg, 72 ft  •  lb)

6. Remove: 

• drive sprocket nut

7. Install: 

• transfer gear oil pump gasket
• transfer gear oil pump 

1

 

NOTE:

_ 

Apply locking agent (LOCTITE

®

) only to the

threads of the transfer gear oil pump bolts (M6

×

 25 mm) bolts 

2

. 

New

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

5 - 93

ENG

CRANKCASE

CRANKCASE

Order

Job/Part

Q’ty

Remarks

Separating the crankcase

Remove the parts in the order listed. 

Engine

Refer to “ENGINE”. 

Camshafts

Refer to “CAMSHAFTS”. 

Pistons

Refer to “CYLINDERS AND PISTONS”. 

Shift shaft

Refer to “SHIFT SHAFT AND STOPPER
LEVER”. 

Generator rotor

Refer  to  “GENERATOR AND STARTER
CLUTCH”. 

1

Generator shaft end cover

1

2

Oil delivery pipe

1

3

Engine oil pump driven gear stopper

1

5 - 94

ENG

CRANKCASE

Order

Job/Part

Q’ty

Remarks

4

Engine oil pump driven gear

1

5

Left crankcase

1

6

Dowel

2

7

Joint pipe

1

8

Right crankcase

1

For installation, reverse the removal 
procedure.

5 - 95

ENG

CRANKCASE

Order

Job/Part

Q’ty

Remarks

Removing the baffle plate and 
bearings

Remove the parts in the order listed. 

Crankshaft

Refer to “CRANKSHAFT AND CON-
NECTING RODS”. 

Transmission

Refer to “TRANSMISSION”. 

1

Baffle plate

1

2

Oil  seal

1

3

Bearing

4

For installation, reverse the removal 
procedure.

5 - 96

ENG

CRANKCASE

EAS00386

DISASSEMBLING THE CRANKCASE

NOTE:

_ 

Loosen the generator shaft bolt before remov-
ing the generator rotor. 

1. Remove: 

• generator shaft bolt 

1

 

NOTE:

_ 

While the holding the generator rotor 

2

 with

the primary sheave holder 

3

, loosen the gen-

erator shaft bolt. 

Primary sheave holder

YS-01880-A

2. Remove: 

• crankcase bolts
• holder

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. 

• Loosen the bolts in decreasing numerical

order (refer to the numbers in the illustra-
tion). 

• The numbers embossed on the crankcase

indicate the crankcase tightening sequence. 

È

Right crankcase

É

Left crankcase

M8 

×

 100 mm bolts: 

1

, 

2

M8 

×

 80 mm bolt: 

3

M6 

×

 105 mm bolt: 

K

M6 

×

 85 mm bolts: 

9

, 

C

M6 

×

 75 mm bolts: 

D

, 

E

M6 

×

 60 mm bolts: 

4

 ~ 

7

M6 

×

 40 mm bolts: 

8

, 

0

 ~ 

B

, 

F

 ~ 

J

È

É

5 - 97

ENG

CRANKCASE

3. Turn: 

• shift drum segment

NOTE:

_ 

Turn the shift drum segment 

1

 to the position

shown in the illustration. In this position, the
shift drum segment’s teeth will not contact the
crankcase during crankcase separation. 

4. Remove: 

• right crankcase

CAUTION:

_ 

• First check that the shift drum segment’s

teeth then remove the right crankcase. 

• Tap on one side of the crankcase with a

soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crank-
case halves separate evenly. 

EAS00399

CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a

mild solvent. 

2. Thoroughly clean all the gasket surfaces

and crankcase mating surfaces.

3. Check: 

• crankcase 

Cracks/damage 

→

 Replace. 

• oil delivery passages 

Obstruction 

→

 Blow out with compressed

air.

5 - 98

ENG

CRANKCASE

EAS00401

CHECKING THE BEARINGS AND OIL 
SEALS

1. Check: 

• bearings 

Clean and lubricate the bearings, then
rotate the inner race with your finger. 
Rough movement 

→

 Replace.

2. Check: 

• oil seals 

Damage/wear 

→

 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.

CHECKING THE ENGINE OIL PUMP DRIVE

1. Check: 

• oil pump drive gear 

1

 

• oil pump driven gear 

2

 

Chips/pitting/roughness/wear 

→

 Replace

the defective part(s).

5 - 99

ENG

CRANKCASE

EAS00416

ASSEMBLING THE CRANKCASE

1. Apply: 

• sealant 

(onto the crankcase mating surfaces)

NOTE:

_ 

Do not allow any sealant to come into contact
with the oil gallery. 

2. Install: 

• dowel pins 

1

 

• joint pipe 

2

 

Quick Gasket

®

 

ACC-11001-05-01

3. Install: 

• left crankcase 

(onto the right crankcase)

NOTE:

_ 

• Turn the shift drum segment 

1

 to the posi-

tion shown in the illustration. In this position,
the shift drum segment’s teeth will not con-
tact the crankcase during crankcase installa-
tion.

• Tap lightly on the left crankcase with a soft-

face hammer.

5 - 100

ENG

CRANKCASE

4. Install: 

• holder 
• crankcase bolts

NOTE:

_ 

• Lubricate the bolt threads with engine oil.
• Tighten each bolt 1/4 of a turn at a time, in

stages and in a crisscross pattern.

• Tighten the bolts in numerical order (refer to

the numbers in the illustration).

È

Left crankcase

É

Right crankcase

M8 

×

 100 mm bolts: 

1

, 

2

M8 

×

 80 mm bolt: 

3

M6 

×

 105 mm bolt: 

K

M6 

×

 85 mm bolts: 

9

, 

C

M6 

×

 75 mm bolts: 

D

, 

E

M6 

×

 60 mm bolts: 

4

 ~ 

7

M6 

×

 40 mm bolts: 

8

, 

0

 ~ 

B

, 

F

 ~ 

J

5. Apply: 

• engine oil 

(onto the crankshaft pins bearings and oil
delivery holes)

6. Check: 

• crankshaft and transmission operation 

Rough movement 

→

 Repair.

T

 

R

.

.

Bolt 

1

 ~ 

3

24 Nm (2.4 m  •  kg, 17 ft  •  lb) 

Bolt 

4

 ~ 

K

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

È

É

7. Install: 

• engine oil pump driven gear 

1

 

• engine oil pump driven gear stopper 

2

 

• oil delivery pipe 

3

 

• bolts 

4

 

T

 

R

.

.

10 Nm (1.0 m  •  kg, 7.2 ft  •  lb)

8. Install: 

• generator rotor

Refer to “GENERATOR AND STARTER
CLUTCH”.

5 - 101

ENG

CRANKCASE

9. Install: 

• washer 
• generator shaft bolt 

1

 

NOTE:

_ 

• Apply locking agent (LOCTITE

®

) to the

threads of the generator shaft bolt. 

• While holding the generator rotor 

2

 with the

primary sheave holder 

3

, tighten the gener-

ator shaft bolt. 

Primary sheave holder 

YS-01880-A

T

 

R

.

.

28 Nm (2.8 m  •  kg, 20 ft  •  lb)