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Yamaha XV1700P, XV1700PC. Service Manual - part 30

7 - 28

–

ELEC

STARTER MOTOR

EAS00767

STARTER MOTOR

5 Nm (0.5 m

•

kg, 3.6 ft

•

Ib)

Order

Job/Part

Q’ty

Remarks

Removing the starter motor

Remove the parts in the order listed.

Starter motor lead

Starter motor assembly

For installation, reverse the removal
procedure.

7 - 29

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ELEC

STARTER MOTOR

New

Order

Job/Part

Q’ty

Remarks

Disassembling the starter motor

Remove the parts in the order listed.

Circlip

Refer to “ASSEMBLING THE STARTER
MOTOR”.

Starter motor gear

Starter motor rear cover

Lock

washer

Washer

set

Oil

seal

Bearing

Circlip

Starter motor front cover

Brush

7 - 30

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ELEC

STARTER MOTOR

New

Order

Job/Part

Q’ty

Remarks

Brush holder (along with the brushes)

Refer to “ASSEMBLING THE STARTER
MOTOR”.

Brush seat (along with the brushes)

Bearing

Gasket

Armature

assembly

Starter motor yoke

For assembly, reverse the disassembly
procedure.

7 - 31

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ELEC

STARTER MOTOR

EAS00770

CHECKING THE STARTER MOTOR

1. Check:

• commutator

Dirt

→

Clean with 600 grit sandpaper.

2. Measure:

• commutator diameter

Out of specification

→

Replace the starter

motor.

Commutator wear limit

27.5 mm (1.08 in)

3. Measure:

• mica undercut

Out of specification

→

Scrape the mica to

the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.

NOTE:

The mica of the commutator must be undercut
to ensure proper operation of the commutator.

Mica undercut

1.5 mm (0.06 in)

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ELEC

STARTER MOTOR

4. Measure:

• armature assembly resistances (commuta-

tor and insulation)
Out of specification

→

Replace the starter

motor.

▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼ ▼▼▼

▼

▼▼▼

a. Measure the armature assembly resis-

tances with the pocket tester.

b. If any resistance is out of specification,

replace the starter motor.

▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲ ▲▲▲

▲

▲▲▲

5. Measure:

• brush length

Out of specification

→

Replace the brushes

as a set.

Pocket tester

YU-03112

Armature coil

Commutator resistance

0.0081 ~ 0.0099

Ω

20 °C (68 °F)

Insulation resistance

Above 1 M

Ω

at 20 °C (68 °F)

Brush length wear limit

5 mm (0.2 in)

6. Measure:

• brush spring force

Out of specification

→

Replace the brush

springs as a set.

7. Check:

• gear teeth

Damage/wear

→

Replace the gear.

8. Check:

• bearing
• oil seal

Damage/wear

→

Replace the defective

part(s).

Brush spring force

7.36 ~ 11.04 N (736 ~ 1,104 gf)

7 - 33

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ELEC

STARTER MOTOR

EAS00772

ASSEMBLING THE STARTER MOTOR

1. Install:

• bearing
• brush seat

NOTE:

Align the slot

on the brush seat with the tab

in the starter motor front cover.

2. Install:

• brush holder (along with the brushes)

3. Install:

• armature assembly

4. Install:

• gasket
• starter motor yoke

• circlip

NOTE:

Align the tab

on the brush holder with the

slot

in the starter motor yoke.

New

5. Install:

• bearing
• oil seal
• washer set
• lock washer

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ELEC

STARTER MOTOR

6. Install:

• gasket

• starter motor cover

• bolts

NOTE:

Align the match marks

on the starter motor

yoke with the match marks

on the starter

motor rear cover.

New

7. Install:

• O-rings

• starter motor gear

• circlip

New

7 - 35

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ELEC

CHARGING SYSTEM

EAS00773

CHARGING SYSTEM

CIRCUIT DIAGRAM

(BLACK)

(GRAY)

W W

L W

(BLACK)

(GRAY)

(BLACK)

L Br

B
Y
L

(BLACK)

(BLA

(BLACK)

W B

Br B

L W

OFF

(BLACK)

G L

(BLACK)

L Y

Y G

Y L

Y R

L B

{

}

WIREHARNESS TAIL SUB-WIREHARNESS

(BLACK)

WIREHARNESS INJECTION SUB-WIREHARNESS

Generator

Rectifier/regulator

Battery

Main fuse

7 - 36

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ELEC

CHARGING SYSTEM

EAS00774

TROUBLESHOOTING

Check:
1. main fuse
2. battery
3. charging voltage
4. stator coil resistance
5. wiring connections

(of the entire charging system)

NOTE:

• Before troubleshooting, remove the following

part(s):

1. seat
2. battery compartment
• Troubleshoot with the following special

tool(s).

EAS00738

YES

EAS00739

YES

EAS00775

The battery is not being charged.

Inductive tachometer

YU-8036-A

Pocket tester

YU-03112

1. Main fuse

• Check the main fuse for continuity.

Refer to “CHECKING THE FUSES” in
chapter 3.

• Are the main fuse OK?

Replace the fuse.

2. Battery

• Check the condition of the battery.

Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20 °C (68 °F)

• Is the battery OK?

• Clean the battery

terminals.

• Recharge or

replace the battery.

3. Charging voltage

• Connect the inductive tachometer to the

spark plug lead of cylinder #1.

• Connect the pocket tester (DC 20 V) to the

battery as shown.

Positive tester probe

→

positive battery terminal

Negative tester probe

→

negative battery terminal

• Start the engine and let it run at approxi-

mately 5,000 r/min.

• Measure the charging voltage.

Charging voltage

14 V at 5,000 r/min

NOTE:

Make sure the battery is fully charged.

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ELEC

CHARGING SYSTEM

YES

EAS00776

YES

EAS00779

YES

• Is the charging voltage within specifica-

tion?

The charging circuit
is OK.

4. Stator coil resistance

• Remove the generator cover.
• Disconnect the stator coil assembly cou-

pler from the rectifier/regulator.

• Connect the pocket tester (

Ω

1) to the

stator coil assembly coupler as shown.

Positive tester probe

→

white

Negative tester probe

→

white

Positive tester probe

→

white

Negative tester probe

→

white

• Measure the stator coil resistances.

Stator coil resistance

0.12 ~ 0.20

Ω

at 20 °C (68 °F)

• Is the stator coil OK?

Replace the stator
coil assembly.

Ω×

5. Wiring

• Check the wiring connections of the entire

charging system.
Refer to “CIRCUIT DIAGRAM”.

• Is the charging system’s wiring properly

connected and without defects?

Replace the rectifier/
regulator.

Properly connect or
repair the charging
system’s wiring.

7 - 38

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ELEC

LIGHTING SYSTEM

EAS00780

LIGHTING SYSTEM

CIRCUIT DIAGRAM

(BLACK)

(GRAY)

(BLA

CK)

B
Y
L

(BLA

CK)

(GRA

(BLA

CK)

(GRA

ARK GRA

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLUE)

B
B

(BLUE)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(RED)

(BLUE)

(GREEN)

(RED)

(BLUE)

OFF

(BLACK)

(BLUE)

(L)

N (R)

[

]

{

}

WIREHARNESS

TAIL SUB-WIREHARNESS

(BLACK)

WIREHARNESS

INJECTION SUB-WIREHARNESS

Main switc

Battery

Main fuse

Tacho

light

]

Spee

dom

Hig

am ind

ica

r lig

Spee

dom

lig

light

lay

immer s

witc

ron

t t

sig

l/p

itio

lig

(

left

ron

t t

sig

l/p

itio

light (right

light

Tail/

ake lig

ice

e pla

lig

light

Signaling sys

tem fuse

7 - 39

–

ELEC

LIGHTING SYSTEM

EAS00781

TROUBLESHOOTING

Check:
1. main, headlight and signaling system fuses
2. battery
3. main switch
4. dimmer switch
5. headlight relay
6. wiring connections

(of the entire lighting system)

NOTE:

• Before troubleshooting, remove the following

part(s):

1. seat
2. headlight lens unit
• Troubleshoot with the following special

tool(s).

EAS00738

YES

EAS00739

YES

EAS00749

YES

EAS00784

YES

Any of the following fail to light: head-
light, high beam indicator light, taillight,
position light, license plate light or meter
light.

Pocket tester

YU-03112

1. Main, headlight and signaling system

fuses

• Check the main, headlight and signaling

system fuses for continuity.
Refer to “CHECKING THE FUSES” in
chapter 3.

• Are the main, headlight and signaling sys-

tem fuses OK?

Replace the fuse(s).

2. Battery

• Check the condition of the battery.

Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.

Minimum open-circuit voltage

12.8 V or more at 20 °C (68 °F)

• Is the battery OK?

• Clean the battery

terminals.

• Recharge or

replace the battery.

3. Main switch

• Check the main switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the main switch OK?

Replace the main
switch.

4. Dimmer switch

• Check the dimmer switch for continuity.

Refer to “CHECKING THE SWITCHES”.

• Is the dimmer switch OK?

The dimmer switch is
faulty. Replace the
left handlebar switch.

7 - 40

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ELEC

LIGHTING SYSTEM

YES

EAS00787

YES

EAS00788

CHECKING THE LIGHTING SYSTEM

1. The headlight and the high beam indicator

light fail to come on.

YES

5. Headlight relay

• Remove the headlight relay from the wire

harness.

• Connect the pocket tester (

Ω

1) and bat-

tery (12 V) to the headlight relay terminal
as shown.

• Check the headlight relay for continuity.

Positive battery terminal

→

red/yellow

Negative battery terminal

→

yellow/black

Positive tester probe

→

red/yellow

Negative tester probe

→

green/blue

• Does the headlight relay have continuity

between red/yellow and green/blue?

Replace the head-
light relay.

6. Wiring

• Check the entire lighting system’s wiring.

Refer to “CIRCUIT DIAGRAM”.

• Is the lighting system’s wiring properly

connected and without defects?

Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECK-
ING THE LIGHTING
SYSTEM”.

Properly connect or
repair the lighting
system’s wiring.

R/Y

G/L

R/Y

Y/B

1. Headlight bulb and socket

• Check the headlight bulb and socket for

continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

• Are the headlight bulb and socket OK?

Replace the head-
light bulb, socket or
both.

2. High beam indicator light LED

• Check the LED of the high beam indicator

light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

• Are the high beam indicator light LED OK?

Replace the speed-
ometer assembly.

3. Voltage

• Connect the pocket tester (DC 20 V) to the

headlight and speedometer assembly cou-
plers as shown.

When the dimmer switch is set to “

”

When the dimmer switch is set to “

“

Headlight coupler

7 - 41

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ELEC

LIGHTING SYSTEM

YES

EAS00789

2. The tachometer and speedometer light fails

to come on.

YES

Headlight

Positive tester probe

→

yellow

or green

Negative tester probe

→

black

High beam indicator light

Positive tester probe

→

yellow

Negative tester probe

→

black

Speedometer assembly coupler

• Set the main switch to “ON”.
• Set the dimmer switch to “

” or “

”.

• Measure the voltage (DC 12 V) of yellow

or green

on the headlight coupler,

and yellow

on the speedometer assem-

bly coupler.

• Is the voltage within specification?

This circuit is OK.

The

wiring

circuit

from the main switch
to the headlight cou-
pler is faulty and
must be repaired.

Ch Y

Dg Lg

Ch Y

Dg Lg

1. Tachometer and speedometer light LED

• Check the LED of the tachometer and

speedometer light.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

• Are the tachometer and speedometer light

LED OK?

Replace the tachom-
eter assembly or
speedometer assem-
bly.

2. Voltage

• Connect the pocket tester (DC 20 V) to the

tachometer and speedometer assembly
couplers as shown.

Tachometer assembly coupler

Tachometer light

Positive tester probe

→

brown

Negative tester probe

→

black

Speedometer light

Positive tester probe

→

brown

Negative tester probe

→

black

7 - 42

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ELEC

LIGHTING SYSTEM

YES

EAS00790

3. The tail/brake light fails to come on.

YES

EAS00791

4. The license plate light fails to come on.

YES

Speedometer assembly coupler

• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of brown

on the tachometer and speedometer

light couplers.

• Is the voltage within specification?

This circuit is OK.

The

wiring

circuit

from the main switch
to the tachometer
and speedometer
light couplers is faulty
and must be
repaired.

1. Tail/brake light LED

• Check the LED of the tail/brake light.

Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

• Are the tail/brake light LED OK?

Replace the tail/
brake light assembly.

Ch Y

Dg Lg

Ch Y

2. Voltage

• Connect the pocket tester (DC 20 V) to the

tail/brake light assembly coupler (tail sub-
wire harness side) as shown.

Positive tester probe

→

blue

Negative tester probe

→

black

• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue

on the tail/brake light assembly coupler
(tail sub-wire harness side).

• Is the voltage within specification?

Replace the tail/
brake light assembly.

The wiring circuit
from the main switch
to the tail/brake light
assembly coupler is
faulty and must be
repaired.

1. License plate light bulb and socket

• Check the license plate light bulb and

socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

• Are the license plate light bulb and socket

OK?

Replace the license
plate light bulb,
socket or both.

7 - 43

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ELEC

LIGHTING SYSTEM

YES

EAS00791

5. The front turn signal/position light fails to

come on.

YES

2. Voltage

• Connect the pocket tester (DC 20 V) to the

license plate light connectors (wire har-
ness side) as shown.

Positive tester probe

→

blue

Negative tester probe

→

black

• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue

on the license plate light connectors (wire
harness side).

• Is the voltage within specification?

This circuit is OK.

The

wiring

circuit

from the main switch
to the license plate
light connectors is
faulty and must be
repaired.

1. Front turn signal/position light bulb and

socket

• Check the front turn signal/position light

bulb and socket for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.

• Are the front turn signal/position light bulb

and socket OK?

Replace the front
turn signal/position
light bulb, socket or
both.

2. Voltage

• Connect the pocket tester (DC 20 V) to the

front turn signal/position light connectors
(wire harness side) as shown.

Positive tester probe

→

blue

Negative tester probe

→

black

• Set the main switch to “ON”.
• Measure the voltage (DC 12 V) of blue

on the front turn signal/position light con-
nectors (wire harness side).

• Is the voltage within specification?

This circuit is OK.

The

wiring

circuit

from the main switch
to the front turn sig-
nal/position light con-
nectors is faulty and
must be repaired.

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