Yamaha XV1700PCRC Road Star Warrior User 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.
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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:

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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.

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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