Yamaha XV1700PCR Road Star Warrior Manual

LIT-11616-16-36 5PX-28197-11
XV1700PCR
XV1700PCRC
SUPPLEMENTARY
SERVICE MANUAL

FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
XV1700PCR/XV1700PCRC. For complete service information procedures it is necessary to use this
Supplementary Service Manual together with the following manual.
XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10)
XV1700PCR/XV1700PCRC
SUPPLEMENTARY
SERVICE MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
First Edition, July 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-16-36

EAS00003
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard
to performance and emissions. Proper service with the correct tools is necessary to ensure that the
vehicle will operate as designed. If there is any question about a service procedure, it is imperative
that you contact a Yamaha dealer for any service information changes that apply to this model. This
policy is intended to provide the customer with the most satisfaction from his vehicle and to conform
to federal environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
_
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
A NOTE provides key information to make procedures easier or clearer.
WARNING
CAUTION:
NOTE:

EAS00007
HOW TO USE THIS MANUAL
This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are
laid out with the individual steps in sequential order.
1The manual is divided into chapters. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
2Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section
title(s) appears.
3Sub-section titles appear in smaller print than the section title.
4To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
5Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
6Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
7A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
8Jobs requiring more information (such as special tools and technical data) are described sequen-
tially.

EAS00009
SYMBOLS
The following symbols are not relevant to
every vehicle. Symbols 1to 8indicate the
subject of each chapter.
1General information
2Specifications
3Periodic checks and adjustments
4Chassis
5Engine
6Fuel injection system
7Electrical system
8Troubleshooting
Symbols 9to Findicate the following.
9Serviceable with engine mounted
0Filling fluid
ALubricant
BSpecial tool
CTightening torque
DWear limit, clearance
EEngine speed
FElectrical data
Symbols Gto Lin the exploded diagrams
indicate the types of lubricants and lubrication
points.
GEngine oil
HGear oil
IMolybdenum-disulfide oil
JWheel-bearing grease
KLithium-soap-based grease
LMolybdenum-disulfide grease
Symbols Mto Nin the exploded diagrams
indicate the following.
MApply locking agent (LOCTITE®)
NReplace the part
12
34
56
78
90
AB
CD
EF
GHI
JKL
MN
GEN
INFO
SPEC
CHK
ADJ
CHAS
ENG FI
–+
ELEC TRBL
SHTG
T
R
.
.
EGM
BLS M
LT
New

CONTENTS
SPECIFICATIONS ........................................................................................... 1
GENERAL SPECIFICATIONS ................................................................. 1
ENGINE SPECIFICATIONS .................................................................... 1
CHASSIS SPECIFICATIONS ................................................................... 1
ELECTRICAL SPECIFICATIONS ............................................................ 2
TIGHTENING TORQUES ......................................................................... 2
CHASSIS TIGHTENING TORQUES .................................................... 2
CABLE ROUTING .................................................................................... 3
PERIODIC CHECKS AND ADJUSTMENTS ................................................. 11
INTRODUCTION .................................................................................... 11
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM ................................................ 11
GENERAL MAINTENANCE AND LUBRICATION CHART .................... 12
CHASSIS ................................................................................................ 14
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ............. 14
CHASSIS ....................................................................................................... 16
FRONT AND REAR BRAKES ................................................................ 16
REAR BRAKE MASTER CYLINDER ................................................. 16
REAR SHOCK ABSORBER AND SWINGARM ..................................... 18
ENGINE .......................................................................................................... 22
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ....................... 22
GENERATOR AND STARTER CLUTCH ............................................... 24
STATOR COIL ASSEMBLY ............................................................... 24

– 1 –
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS
Item Standard Limit
Model code 5PX4 (USA)
5PX5 (California)
5PX6 (CDN)
----
----
----
Item Standard Limit
Electronic fuel injection
Model (manufacturer) INP-732 (NIPPON INJECTOR) ----
Quantity 2 ----
Crankshaft
Width A 132.8 ~ 133.2 mm (5.228 ~ 5.244 in) ----
Max. runout C ---- 0.04 mm
(0.0016 in)
Big end side clearance D 0.320 ~ 0.474 mm (0.0126 ~ 0.0187 in) ----
Big end radial clearance E 0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) 0.09 mm
(0.0035 in)
Crankshaft journal-to-crankshaft-
journal bearing clearance
0.032 ~ 0.062 mm (0.0012 ~ 0.0024 in) 0.1 mm
(0.0039 in)
Fuel pump
Pump type Electrical ----
Model (manufacturer) 5PX (MITSUBISHI) ----
Max. consumption amperage 5 A ----
Output pressure 392 ~ 588 kPa
(3.92 ~ 5.88 kg/cm2, 55.7 ~ 83.6 psi)
----
Item Standard Limit
Front tire
Tire type Tubeless ----
Size 120/70 ZR 18 M/C (59 W)
120/70 ZR 18 (59 W)
----
Model (manufacturer) D220F ST G (DUNLOP)/
BT020F G (BRIDGESTONE)
----
A
D
CC
E
GENERAL SPECIFICATIONS/
ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS

–2 –
SPEC
ELECTRICAL SPECIFICATIONS
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm2, 36 psi) ----
90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kgf/cm2, 36 psi) ----
High-speed riding 250 kPa (2.5 kgf/cm2, 36 psi) ----
* Load is the total weight of the cargo,
rider, passenger and accessories.
Min. tire tread depth ---- 1.0 mm
(0.04 in)
Rear tire
Tire type Tubeless ----
Size 200/50 ZR 17 M/C (75 W)
200/50 ZR 17 (75 W)
----
Model (manufacturer) D220 ST (DUNLOP)/
BT020R (BRIDGESTONE)
----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm2, 36 psi) ----
90 kg (198 lb) ~ Maximum load* 290 kPa (2.9 kgf/cm2, 42 psi) ----
High-speed riding 250 kPa (2.5 kgf/cm2, 36 psi) ----
* Load is the total weight of the cargo,
rider, passenger and accessories.
Min. tire tread depth ---- 1.0 mm
(0.04 in)
Item Standard Limit
Ignition coils
Model (manufacturer) J0447 (DENSO) ----
Minimum ignition spark gap 6 mm (0.24 in) ----
Primary coil resistance 1.32 ~ 1.78 Ω----
Secondary coil resistance 12 ~ 18 kΩ----
Charging system
System type AC magneto ----
Model (manufacturer) F5PX (YAMAHA) ----
Nominal output 14 V/31 A at 5,000 r/min ----
Stator coil resistance/color 0.13 ~ 0.19 Ω/W–W ----
Item Thread size Tightening torque Remarks
Nm m·kg ft·lb
Rider footrest bracket and frame M10 48 4.8 35 LT
Rear fender and turn signal light bracket (upper) M6 7 0.7 5.1
Rear fender and turn signal light bracket (lower) M6 9 0.9 6.5
Canister and rider footrest bracket (For California
only)
M6 9 0.9 6.5
Item Standard Limit
CHASSIS SPECIFICATIONS/
ELECTRICAL SPECIFICATIONS/TIGHTENING TORQUES

–3 –
SPEC
EB206000
CABLE ROUTING
1Brake hose
2Clutch cable
3Rectifier/regulator
4Rectifier/regulator lead
5Rear brake light switch lead
6Horn lead
7Stator coil assembly lead
ÈFasten the rectifier/regulator
lead, horn lead, and rear brake
light switch lead with a plastic
locking tie to the frame.
ÉFasten the stator coil assem-
bly lead and rectifier/regulator
lead with a plastic clamp.
ÊFasten the rear brake light
switch lead, horn lead, and
stator coil assembly lead with
a plastic locking tie to the
frame.
ËFasten the stator coil assem-
bly lead, horn lead, and rear
brake light switch lead with a
plastic locking tie to the frame.
2
1
3
4
5
6
7
1
1
Ë
Ê
É
È
CABLE ROUTING

–4 –
SPEC
1Tachometer couplers
2Right handlebar switch coupler and speedome-
ter couplers
3Main switch coupler
4Left handlebar switch couplers
5Left and right turn signal/position light connec-
tors
ÈSecure the wire harness in the holder at the
white tape on the harness.
ÉRoute each lead behind the headlight assembly
bracket bolts.
A
A
2
1
5
4
3
ÉÉ
È
CABLE ROUTING

–5 –
SPEC
1Throttle cable 1 and throttle cable 2
2Clutch cable
3Atmospheric pressure sensor
4Spark plug cap (ignition coil 1-L spark plug lead)
5Horn lead
6Crankshaft position sensor lead
7Horn 2
8Sidestand switch lead
9Starter motor lead
0Spark plug cap (ignition coil 2-L spark plug lead)
ARear brake light switch
ÈPass throttle cable 1 and throttle cable 2 through
the cable guide, and then fasten them with a
plastic holder.
ÉFasten the engine stop switch lead, horn lead,
and oil temperature sensor lead with a plastic
locking tie.
ÊFasten the sidestand switch lead, starter motor
lead, crankshaft position sensor lead, decom-
pression solenoid lead, cylinder identification
sensor lead, speed sensor lead, and neutral
switch lead with a plastic locking tie.
Ï
Î
Ð
Í
Ì
Ë
Ê
É
È
12
3
4
5
6
7
8
9
0
A
Ñ
CABLE ROUTING

–6 –
SPEC
ËFasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking
tie.
ÌFasten the starter motor lead and side stand switch lead with a plastic locking tie to the frame.
ÍFasten the starter motor lead, fuel tank drain hose, and fuel tank/air filter breather hose with a plastic band
to the frame.
Be sure not to pinch the fuel tank drain hose or the fuel tank/air filter breather hose.
ÎFasten the starter motor lead with a plastic locking tie.
ÏClamp the clutch cable between the locknut and washer with a plastic clamp.
ÐTo the engine.
ÑFasten the rear brake light switch with a plastic locking tie.
Ï
Î
Ð
Í
Ì
Ë
Ê
É
È
12
3
4
5
6
7
8
9
0
A
Ñ
CABLE ROUTING

–7 –
SPEC
1Ignition coil 1
2Atmospheric pressure sensor lead
3Ignition coil 2
4Ignition coil 2 lead
5Rear brake light switch coupler
6Rectifier/regulator lead and horn lead
7Linear control valve lead
8Ignition coil 1 lead
9Fuel return hose
0Fuel inlet hose
ÈTo the rectifier/regulator, horn 1, and rear brake
light switch.
É30 ~ 50 degrees
Ê40 ~ 60 degrees
A
C
B
2
1
6
7
9
A
BC
8
54
0
D-D E-E
D
D
È
3ÉÊ9
E
E
CABLE ROUTING

–8 –
SPEC
1Oil temperature sensor
2Fuel hose
3Spark plug cap (ignition coil 1-R
spark plug lead)
4Injector lead
5Throttle position sensor lead
6Intake air pressure sensor 1
7Intake air temperature sensor
coupler
8Intake air pressure sensor lead
9Intake air pressure sensor 2
0Throttle cables
ABrake hose
BSpark plug cap (ignition coil 2-R
spark plug lead)
CEngine temperature sensor lead
DStator coil lead
ENeutral switch lead
FSpeed sensor lead
GMain wire harness
HIgnition coil 1-R spark plug lead
ILean angle cut-off switch lead
JCrankshaft position sensor lead
KSidestand switch lead
LStarter motor lead
MHorn 2 lead
NOil temperature sensor lead
C
C
B
B
A
A
E
0
A
9
8
7
6
5
4
3
2
1
F
E
D
C
B
J
I
M
L
K
G
H
G
H
G
2
A-A B-B C-C D-D
E
Ø
Ò
Ó
Ï
Í
Ì
Ë
Ê
É
È
Ö
×
Ô
Õ
Ð
Ñ
Î
D
D
N
Ù
CABLE ROUTING

–9 –
SPEC
ÈTo the battery box.
ÉFasten the main wire harness and fuel hose with
a plastic locking tie to the frame.
ÊFasten the main wire harness and spark plug
lead #3 with a plastic locking tie to the frame.
ËFasten the throttle position sensor lead, engine
temperature sensor lead, and injector lead with
a plastic locking tie to the fuel delivery pipe.
ÌFasten the main wire harness and spark plug
lead #3 with a plastic locking tie.
ÍFasten the main wire harness, intake air pres-
sure sensor lead #2, ignition coil 1-R spark plug
lead, and intake air temperature sensor coupler
with a plastic locking tie.
ÎFasten the rear brake light switch lead and igni-
tion coil lead #2 with a plastic band.
ÏFasten the main wire harness and intake vac-
uum hose with a plastic locking tie.
C
C
B
B
A
A
E
0
A
9
8
7
6
5
4
3
2
1
F
E
D
C
B
J
I
M
L
K
G
H
G
H
G
2
A-A B-B C-C D-D
E
Ø
Ò
Ó
Ï
Í
Ì
Ë
Ê
É
È
Ö
×
Ô
Õ
Ð
Ñ
Î
D
D
N
Ù
CABLE ROUTING

–10 –
SPEC
ÐTo the injector sub lead.
ÑTo the engine temperature sensor.
Ò10 ~30 mm (0.4 ~1.2 in)
ÓPosition the gray mark on the stator coil lead at
the center of the bolt, and then fasten it with a
plastic locking tie.
ÔTo the stator coil.
ÕTo the decompression solenoid and cylinder
identification sensor.
ÖTo the neutral switch.
×To the speed sensor.
ØFasten the crankshaft position sensor lead, side-
stand switch lead, lean angle cut-off switch lead,
starter motor lead, and horn lead with a plastic
locking tie.
ÙFasten the oil temperature sensor lead with the
lead holder.
C
C
B
B
A
A
E
0
A
9
8
7
6
5
4
3
2
1
F
E
D
C
B
J
I
M
L
K
G
H
G
H
G
2
A-A B-B C-C D-D
E
Ø
Ò
Ó
Ï
Í
Ì
Ë
Ê
É
È
Ö
×
Ô
Õ
Ð
Ñ
Î
D
D
N
Ù
CABLE ROUTING

– 11 –
CHK
ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
No. ITEM ROUTINE
INITIAL ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000 mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000
mi
(19,000 km)
or
18 months
16,000
mi
(25,000 km)
or
24 months
20,000
mi
(31,000 km)
or
30 months
1 * Valve clearance • Check valve clearance when engine is cold.
• Adjust if necessary. Every 16,000 mi (25,000 km)
2 * Spark plugs
• Check condition.
• Adjust gap and clean.
• Replace at 8,000 mi (13,000 km) or
12 months and thereafter every 8,000 mi
(13,000 km) or 12 months.
√Replace. √Replace. √
3*
Crankcase ventila-
tion system
• Check ventilation hose for cracks or damage.
• Replace if necessary. √√√√√
4 * Fuel line • Check fuel hose for cracks or damage.
• Replace if necessary. √√√√√
5 * Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
√√√√√
6*
Electronic fuel
injection
• Check and adjust engine idle speed and syn-
chronization.
• Adjust cable free play.
√√√√√√
7*
Evaporative
Emission control
system (For
California only)
• Check control system for damage.
• Replace if necessary. √√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
INTRODUCTION/PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM

–12 –
CHK
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
GENERAL MAINTENANCE AND LUBRICATION CHART
No. ITEM ROUTINE TYPE
INITIAL ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000 mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000
mi
(19,000 km)
or
18 months
16,000
mi
(25,000 km)
or
24 months
20,000
mi
(31,000 km)
or
30 months
1Engineoil •Change. —√√√√√√
2*
Engine oil filter
cartridge •Replace. —√√√
3 * Air filter elements
•Check condition and for
damage.
•Replace if necessary.
—√√√√√
4 * Front brake
•Check operation and
fluid leakage.
•Correct if necessary.
—√√√√
Replace
brake
fluid.
√
5 * Rear brake
•Check operation and
fluid leakage.
•Correct if necessary.
—√√√√
Replace
brake
fluid.
√
6*Clutch
•Check operation and
free play.
•Correct if necessary.
—√√√√√√
7 * Transfer case oil
•Check vehicle for leak-
age.
•Replace every
16,000 mi (25,000 km)
or 24 months.
SAE 80 API “GL-4”
hypoid gear oil Change. Check. Change.
8*
Throttle grip hous-
ing and cable
•Check operation and
free play.
•Adjust the throttle cable
free play if necessary.
•Lubricate the throttle
grip housing and cable.
—√√√√√
9 * Control cables •Apply chain lube thor-
oughly.
Yamaha Chain and
Cable Lube or
engine oil (API SE)
10W-30
√√√√√√
10 * Rear arm pivot
bearing
•Check bearing assem-
bly for looseness.
•Moderately repack
every 16,000 mi
(25,000 km) or
24 months.
Lithium-soap-
based grease √Repack.
11 Brake and clutch
lever pivot shafts
•Lubricate.
•Apply grease lightly.
Lithium-soap-
based grease (all-
purpose grease)
√√√√√
12 Brake pedal and
shift pedal shafts
•Lubricate.
•Apply grease lightly.
Lithium-soap-
based grease (all-
purpose grease)
√√√√√
13 * Sidestand pivot
•Check operation and
lubricate.
•Apply grease lightly.
Lithium-soap-
based grease (all-
purpose grease)
√√√√√
14 * Sidestand switch •Check and clean or
replace if necessary. —√√√√√√
15 * Front fork •Check operation and for
leakage. —√√√√√
16 * Steering bearings
•Check bearing assem-
bly for looseness.
•Moderately repack
every 16,000 mi
(25,000 km) or
24 months.
Lithium-soap-
based grease (all-
purpose grease)
√√√
Repack. √

–13 –
CHK
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi
(7,000 km) or 6 months.
NOTE:
_
•Air filters
•This model’s air filters are equipped with disposable oil-coated paper elements, which must not
be cleaned with compressed air to avoid damaging them.
•The air filter elements need to be replaced more frequently when riding in unusually wet or dusty
areas.
•Hydraulic brake service
•After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
•Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
•Replace the brake hoses every four years and if cracked or damaged.
17 * Wheel bearings •Check bearings for
smooth rotation. —√√√√√
18 * Rear suspension
link pivots
•Lubricate.
•Apply grease lightly.
Lithium-soap-
based grease √
19 * Drive belt •Check belt tension.
•Adjust if necessary. —√Every 2,500 mi (4,000 km)
No. ITEM ROUTINE TYPE
INITIAL ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000 mi
(7,000 km)
or
6 months
8,000 mi
(13,000 km)
or
12 months
12,000
mi
(19,000 km)
or
18 months
16,000
mi
(25,000 km)
or
24 months
20,000
mi
(31,000 km)
or
30 months