Yamaha XV1700P 2002, Assembly Manual

Page 1: ...Corrected 2002 LIT 11666 1 5 37 5PX 28107 1 0 ...

Page 2: ...der Particularly important information is distinguished in this manual by the following notations UP ln tall so that the arrow mark faces upward The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person inspecting or repairing the motorcycle ...

Page 3: ...SETUP PROCEDURES 1 Page 1 ...

Page 4: ...ar tt t he top of thelower handlebar holdEn C Tighten the bolts to specified torque 1 Master cylinder 2 Bracket 3 Hexagon socket bolt 4 Front brake light switch connector A Align the punch mark on the handlebar with the gap of the master cylinder bracket 8 Tighten the bolts in stages and maintain an equal gap on each side of the bracket C Check the brake lever for smooth action Proper hose routing...

Page 5: ...ion Refer to CABLE ROUTING 1 Clutch cable 2 Boot 3 Clutch switch coupler A Pass the clutch cable through the wire guide B Check the clutch lever for smooth action CA u n a N Proper cable routing is essential to assure safe motorcycle operation Refer to CABLE ROUTING 1 Plastic clamp large 2 Plastic clamp small A Clamp the handlebar switch lead left B Clamp the handlebar switch lead right NOTE Refer...

Page 6: ... ROUTING Reflector bracket 1 left and right 2 Reflector 3 Flange nut 4 Brake hose holder left an d right 5 Flange nut 6 Front fender 7 Grommet 8 Flange bolt 9 Flange bolt A Tighten the front fender bol1 to specified torque Tightening torque 16Nm 1 6m ekg 11 ft lb Proper cable routing is essential to assure safe motorcycle operation Refer to CABLE ROUTING 1 c 1 c 1 v 1 v 2 v 2 v 2 v d 5 0 20 2 v 2 ...

Page 7: ...s off the brake disc as the brake pads will be forced shut F Make sure the axle is properly torqued Tightening torque 72 Nm 7 2 m kg 52ft lb 1 Air duct cover 2 Hexagon bolt A Tighten the air duct cover screws to specified torque Tightening torque 7 Nm 0 7 m kg 5 1 ft lb 2 1 1 1 2 4 4 2 4 1 2 v s c v v d 8 0 31 e 35 1 38 d 6 0 24 e 14 o ss d 10 0 40 e 20 o ao Before tightening the pinch bolt stroke...

Page 8: ... PREDELIVERY SERVICE E Place the ECU on the battery cover B Flr5t connect the Ef lead Red color lead to the Ef terminal NOTE C Connect the 8 lead Black color Refer to CABLE ROUTI S lead to the e terminal D Place the couplers in the battery cover 1 Cover 2 Tool kit 3 Band 4 Rubber damper 5 Seat A Use the adhesive strips on the rubber dampers to attach the rubber dampers to the frame 1 c 1 2 2 c 1 P...

Page 9: ... fasten them with a plastic holder liD Route the negative battery lead on top of the other leads A A g Place the couplers in the battery cover IQ When installing the ECU be sure not to pinch fuel pump lead and tail brake light lead between the ECU and battery cover I Fasten the decompression solenoid lead speed sensor lead cylinder identification sensor lead sidestand switch lead pickup coil lead ...

Page 10: ...ke hose n When installing the throttle cable holder be sure to leave a space of 25 mm between the holder and the right handlebar switch liD When installing the brake hose and throttle cable holder be sure to leave a space of 60 mm between the holder and the brake hose end A A B B C C Page 8 ...

Page 11: ...ADJUSTMENTS AND PREDELIVERY SERVICE J n Page 9 ...

Page 12: ...42 US qt C Idling speed adjustment 1 Start the engine and let it arm up for several tniflutes 2 Remove Seat 3 Check Engine idling speed Out of specification t Adjust Engine idling speed 850 950 r min 2009 Yamaha changed to 10W40 up to 40F then 20W50 Recommended oil Yamalube 4 20W40 or SAE 20W40 motor oil Oil capacity periodic oil change 3 7 L 3 3 Imp qt 3 9 US qt NOTE Recommended oil classificatio...

Page 13: ...cknut 2 Adjust Loosen the locknut D T4m the adjuster In directlon fi or until the specified free play is obtained Direction 6 Free play is increased Direction Free play is decreased Tighten the locknut A WARNING After adjusting tum the handlebar to the right and to the left to ensure that this does not cause the engine Idling speed to change Qitibbi After adjusting the front brake lever free play ...

Page 14: ...Rear brake fSi_ijfil N v _ e After adjusting the brake pedal height make sure that there Is no brake drag A WARNING A soft or spongy feeling In the brake pedal may Indicate the presence of air in the brake system This air must be removed by bleeding the brake system before the motorcycle Is operated Air In the brakesystemwillconsiderably reducebraldng performance andcanresultIn aloss of controland...

Page 15: ...l to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal i Repeat steps e to h until all the air bubbles have disappeared from the brake fluid 1 2 Adjust Pull the boot G off Loosenthe locknut Turn the adjuster in direction fi or until the specified free play is obtained Direction b Free play is increased Direction Free p...

Page 16: ...rks of the level window on the lower drive belt cover are in units of 5 mm 0 2 in Use them as a standard for measuring the drive belt slack Measure the drive belt slack when the drive lt has been pushed with 4 5 kg 10 lbs of pressure using a belt tension gauge 4 Adjust NO Piace the motorcycle on a suitable stand so that the rear wheel is elevated Loosen the wheel axle nut Loosen the brake caliper ...

Page 17: ...Direction Spring preload is harder Direction S Spring preload is softer N Headlight beam adjustment 1 Adjust Headlight beam vertically Turn the adjuster D in direction or Direction Headlight beam Is raised Direction li Headlight beam Is lowered 1C Adjuster position Standard 5 Minimum Maximum 8 1 ciina Groovesare provided toIndicatetheadjustment position Make sure that each fork leg Is adjusted to ...

Page 18: ... severe bums etc Contains sulphuric acid Avoid contac1 with skin eyes or clothing Antidote External Flush with waler lntemai Drink large quantities of water or mUk Follow with milk of magnesia beaten egg or vegetable oil Call physician Immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame clgarett si etc away Ventilate...

Page 19: ...50 kPa 290 kPa I 2 50 kg cm2 36 psi 2 90 kg cm2 41 psi I li High spee riding 250 kPa 250 kPa I 2 50 kg cm2 36 psi 2 50 kg cm2 36 psi Load is t_he total weight of cargQ rider passenger cargo and accessories I I STANDAap EQUIPMENT OWNER S TOOL KIT No Part name Q ty No Part name Q ty 1 Owner s manual 1 1 Owner s tool bag 1 2 Owner s tool kit 1 2 Pliers 1 3 Open end wrench 8 10 1 4 Open end wrench 10 ...

Page 20: ...t Transfer gear case bracket and frame Muffler bracket and frame Muffler bracket and muffler Ignition coil Swingarm pivot shaft Relay arm and swingarm Relay arm and connecting rod Relay arm and rear shock absorber Rear shock absorber connecting rod and frame Upper drive belt cover and swingarm Lower drive belt cover and swingarm Rear fender bracket and frame Rear fender bracket and rear fender Fue...

Page 21: ...rk guard and front fork Front fork guard and front fork Front fender and front fork leg Cap bolt and outer tube Damper rod assembly bolt Reflector bracket front Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Rear brake bracket and brake pedal Shift shaft and shift pedal Thread size M8 M6 M6 M6 M6 M6 M6 M10 M12 M12 M10 M10 M6 M8 M8 M6 M10 M8 M18 M8 M18 M10 M10 M6 M8 ...

Page 22: ... PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2003 04 2 8x1 CR E ...