Yamaha XV17ASZ Service Manual

LIT-11616-17-09 4WM-28197-E1XV17AS(C)XV17ASS(C)XV17ATS(C)SUPPLEMENTARYSERVICE MANUAL

– 3 –SPECENGINE SPECIFICATIONSCamshaft exhaust cam dimensionsMeasurement A 38.236 ~ 38.336 mm (1.5054 ~ 1.5093 in) 38.136 mm (1.5014 in)Measurement B

– 4 –SPECENGINE SPECIFICATIONSPistonsPiston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm (0.006 in)Diameter D 96.960 ~ 96.975 mm

– 5 –SPECENGINE SPECIFICATIONSTransmissionTransmission type Constant mesh, 5-speed ----Primary reduction system Spur gear ----Primary reduction rati

– 6 –SPECCHASSIS SPECIFICATIONSCHASSIS SPECIFICATIONSItem Standard LimitFront wheelWheel type Cast wheelSpoke wheel (XV17A for CDN)--------Rim Size 1

– 7 –SPECCHASSIS SPECIFICATIONSFront tireTire type TubelessWith tube (XV17A for CDN)--------Size 130/90–16M/C 67H ----Model (manufacturer) USA CDNG7

– 8 –SPECCHASSIS SPECIFICATIONSFront brakesBrake type Dual-disc brake ----Operation Right-hand operation ----Brake lever free play (lever end) 2 ~ 5

– 9 –SPECCHASSIS SPECIFICATIONSDrive beltModel (manufacturer) UBD-0681 ----Drive belt slack (on a sidestand) 6 ~ 8 mm (0.24 ~ 0.31 in) ----Drive bel

– 10 –SPECELECTRICAL SPECIFICATIONSELECTRICAL SPECIFICATIONSItem Standard LimitSystem voltage 12 V ----Ignition systemIgnition system type Transistor

– 11 –SPECTIGHTENING TORQUESTIGHTENING TORQUESENGINE TIGHTENING TORQUESItem FastenerThread sizeQ’ty Tightening torqueRemarksNm m · kgf ft · lbCylinder

– 12 –SPECTIGHTENING TORQUESCHASSIS TIGHTENING TORQUESItem Thread sizeTightening torqueRemarksNm m · kgf ft · lbUpper bracket and inner tube M6 18 1.8

FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theXV17AS(C)/XV17ASS(C)/XV17ATS(C). For complete ser

– 13 –SPECCABLE ROUTINGEB206000CABLE ROUTING1Right handlebar switch lead2Throttle cables3Brake hoses4Clutch cable5Left handlebar switch lead6Air induc

– 14 –SPECCABLE ROUTING1 Rectifier/regulator lead2 Rear brake light switch lead3 Wire harness4 Seat lock cable5 Throttle position sensor coupler6 Carb

– 15 –SPECCABLE ROUTINGÈ Fasten the rectifier/regulator lead and rear brakelight switch lead with the plastic holders.É Pass the left handlebar switch

– 16 –SPECCABLE ROUTINGÐ Fasten the horn lead and starter motor lead tothe frame with the plastic locking tie.Ñ Fasten the starter motor lead with the

– 17 –SPECCABLE ROUTING1 Wire harness2 Spark plug cap #13 Fuel sender lead4 Negative battery lead5 Positive battery lead6 Tail/brake light lead7 Start

– 18 –SPECCABLE ROUTINGÈ To fuel senderÉ Fasten the wire harness and seat lock cable tothe frame with the plastic band.Ê Fasten the wire harness, fuel

– 19 –SPECCABLE ROUTINGÒ Fasten the speed sensor lead, decompressionsolenoid lead, pickup coil lead, neutral switchlead, stator coil lead, sidestand s

– 20 –SPECCABLE ROUTING1 Turn signal relay2 Relay unit3 Battery4 Oil tank breather hose5 Fuel tank breather hose6 Meter assembly lead7 Throttle cables

– 21 –SPECCABLE ROUTINGÈ Fasten the fuel tank breather hose with the plas-tic holder.É Fasten the throttle cables and fuel tank breatherhose with the

– 22 –SPECCABLE ROUTING1 Left handlebar switch lead2 Throttle cables3 Right handlebar switch lead4 Fuel tank breather hose5 Oil tank breather hose6 Re

EAS00003NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamahadealers and their qualified mechanics. It is not p

– 23 –SPECCABLE ROUTINGÈ Fasten the left handlebar switch lead with theplastic holders.É Fasten the right handlebar switch lead with theplastic holder

– 24 –SPECCABLE ROUTINGEvaporative emission control system (for California)1 Compensator2 Compensator breather hose3 3-way-joint-to-compensator hose4

– 25 –SPECCABLE ROUTINGÈ Fasten the 3-way-joint-to-compensator hosewith the plastic holder.É To solenoid valveÊ Fasten the compensator breather hose a

– 26 –SPECCABLE ROUTING1 Carburetor-to-surge-tank hose2 3-way-joint-to-surge-tank hose3 Surge tank4 Surge-tank-to-3-way-joint hose5 Carburetor-to-char

– 27 –CHKADJEAS00036PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjus

– 28 –CHKADJGENERAL MAINTENANCE AND LUBRICATION CHART* Since these items require special tools, data and technical skills, have a Yamaha dealer perfor

– 29 –CHKADJGENERAL MAINTENANCE AND LUBRICATION CHARTNOTE:From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 m

– 30 –CHKADJSEATS AND SIDE COVERSSEATS AND SIDE COVERSOrder Job/Part Q’ty RemarksRemoving the seats and side coversRemove the parts in the order liste

– 31 –CHKADJFUEL TANKEAS00040FUEL TANK1216534T R..7 Nm (0.7 m • kg, 5.1 ft • Ib)Order Job/Part Q’ty RemarksRemoving the fuel tankRemove the parts in t

– 32 –CHASEAS00514CHASSISFRONT WHEEL AND BRAKE DISCSOrder Job/Part Q’ty RemarksRemoving the front wheel and brake discsRemove the parts in the order l

EAS00007HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all insta

– 33 –CHASREAR WHEEL, BRAKE DISC AND REAR WHEELPULLEYEAS00550REAR WHEEL, BRAKE DISC AND REAR WHEEL PULLEYOrder Job/Part Q’ty RemarksRemoving the rear

– 34 –CHASREAR WHEEL, BRAKE DISC AND REAR WHEELPULLEYOrder Job/Part Q’ty Remarks7 Right adjusting plate 18 Left adjusting plate 19 Rear wheel axle 110

– 35 –CHASFRONT AND REAR BRAKESEAS00577FRONT AND REAR BRAKESFRONT BRAKE PADS32266541T R..6 Nm (0.6 m • kg, 4.3 ft • Ib)T R..40 Nm (4.0 m • kg, 29 ft •

– 36 –CHASFRONT AND REAR BRAKESEAS00580REPLACING THE FRONT BRAKE PADSThe following procedure applies to both brakecalipers.NOTE:_ When replacing the b

– 37 –CHASFRONT AND REAR BRAKES5. Install: • brake pad shims(onto the brake pads)• brake pads • brake pad spring NOTE:_ Always install new brake pads

– 38 –CHASFRONT AND REAR BRAKESEAS00586REAR BRAKE MASTER CYLINDEROrder Job/Part Q’ty RemarksRemoving the rear brake master cyl-inderRemove the parts i

– 39 –CHASFRONT AND REAR BRAKESOrder Job/Part Q’ty Remarks11 Left footrest assembly 112 Cotter pin 113 Pin 114 Brake master cylinder 1For installation

– 40 –CHASFRONT AND REAR BRAKESEAS00613FRONT BRAKE CALIPERS43655T R..40 Nm (4.0 m • kg, 29 ft • Ib)NewT R..30 Nm (3.0 m • kg, 22 ft • Ib)12Order Job/P

– 41 –CHASFRONT AND REAR BRAKESEAS00615767874647321NewNewNewNewT R..6 Nm (0.6 m • kg, 4.3 ft • Ib)55Order Job/Part Q’ty RemarksDisassembling the front

– 42 –CHASFRONT AND REAR BRAKESEAS00625DISASSEMBLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.NOTE:_ Befor

SYMBOLSThe following symbols are not relevant toevery vehicle.Symbols 1 to 8 indicate the subject of eachchapter.1General information2Specifications3P

– 43 –CHASFRONT AND REAR BRAKESEAS00633CHECKING THE FRONT BRAKE CALIPERSRecommended brake component replacement scheduleBrake pads If necessaryPiston

– 44 –CHASFRONT AND REAR BRAKESEAS00638ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.

– 45 –CHASFRONT AND REAR BRAKES4. Fill: • brake master cylinder reservoir (with the specified amount of the recom-mended brake fluid)WARNING_ • Use on

– 46 –CHASFRONT AND REAR BRAKES7. Check: • brake lever operation Soft or spongy feeling → Bleed the brakesystem. Refer to “BLEEDING THE HYDRAULICBRAKE

– 47 –CHASHANDLEBAREAS00664HANDLEBAROrder Job/Part Q’ty RemarksRemoving the handlebarRemove the parts in the order listed.1 Rear view mirror (left and

– 48 –CHASHANDLEBAROrder Job/Part Q’ty Remarks12 Left handlebar switch 113 Handlebar grip 114 Clutch cable 1 Disconnect.15 Clutch lever holder 116 Cab

– 49 –CHASREAR SHOCK ABSORBER AND SWINGARMREAR SHOCK ABSORBER AND SWINGARMOrder Job/Part Q’ty RemarksRemoving the rear shock absorber and swingarmRemo

– 50 –CHASREAR SHOCK ABSORBER AND SWINGARMOrder Job/Part Q’ty Remarks11 Pivot shaft 112 Rear shock absorber and swingarm assembly1For installation, re

– 51 –CHASREAR SHOCK ABSORBER AND SWINGARMOrder Job/Part Q’ty RemarksRemoving the rear shock absorber and swingarmRemove the parts in the order listed

– 52 –CHASREAR SHOCK ABSORBER AND SWINGARMOrder Job/Part Q’ty Remarks11 Spacer/bearing 1/112 Swingarm 113 Dust cover 214 Spacer 115 Bearing 2For insta

CONTENTSSPECIFICATIONS ...1GENERAL SPECIFICATIONS ...

– 53 –CHASDRIVE BELT AND DRIVE PULLEYDRIVE BELT AND DRIVE PULLEYOrder Job/Part Q’ty RemarksRemoving the drive belt and drive pulleyRemove the parts in

– 54 –ENGENGINEROCKER ARMS, PUSH RODS AND VALVE LIFTERS986542543455459534544553587T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)NewNew31Quick Gasket®Quick Gaske

– 55 –ENGROCKER ARMS, PUSH RODS AND VALVE LIFTERS101189101171011101189356645121EEEEEEET R..24 Nm (2.4 m • kg, 17 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 f

– 56 –ENGROCKER ARMS, PUSH RODS AND VALVE LIFTERS2312764521327EET R..10 Nm (1.0 m • kg, 7.2 ft • Ib)T R..10 Nm (1.0 m • kg, 7.2 ft • Ib)EEEEOrder Job/

– 57 –ENGROCKER ARMS, PUSH RODS AND VALVE LIFTERSINSTALLING THE ROCKER ARMS AND PUSH RODSThe following procedure applies to both cylin-ders.1. Install

– 58 –ENGROCKER ARMS, PUSH RODS AND VALVE LIFTERSc. Install the rocker arm base bolts.NOTE:Tighten the rocker arm base bolts in stagesand in a crisscr

– 59 –ENGCLUTCHEAS00274CLUTCHOrder Job/Part Q’ty RemarksRemoving the clutchRemove the parts in the order listed.Clutch cover Refer to “CLUTCH” in chap

– 60 –ENGCLUTCHOrder Job/Part Q’ty Remarks10 Friction plate 111 Clutch damper spring 112 Clutch damper spring seat 113 Clutch boss 114 Thrust washer 1

– 61 –ENGCLUTCHINSTALLING THE CLUTCH BOSS NUT1. Install:• washer• clutch boss nut 1NOTE:• Install the washer on the main axle with the“OUT” mark facin

– 62 –ENGGENERATOR AND STARTER CLUTCHEAS00343GENERATOR AND STARTER CLUTCHOrder Job/Part Q’ty RemarksRemoving the generator rotorRemove the parts in th

CARBURETOR ...71AIR INDUCTION SYSTEM ...

– 63 –ENGCRANKSHAFT AND CONNECTING RODSCRANKSHAFT AND CONNECTING RODSEAS00398CHECKING THE CRANKSHAFT AND CONNECTING RODS1. Measure:• crankshaft runout

– 64 –ENGCRANKSHAFT AND CONNECTING RODSb. Install the big end upper bearing into theconnecting rod and the big end lower bear-ing into the connecting

– 65 –ENGCRANKSHAFT AND CONNECTING RODSWARNINGWhen a bolt is tightened more than thespecified angle, do not loosen them andthen retighten them.Replace

– 66 –ENGCRANKSHAFT AND CONNECTING RODS4. Select:• big end bearings (P1 ~ P2)NOTE:• The numbers a stamped into the crankshaftweb and the numbers b on

– 67 –ENGCRANKSHAFT AND CONNECTING RODS6. Measure:• crankshaft journal bearing inside diameter a Out of specification → Replace the crank-case assembl

– 68 –ENGCRANKSHAFT AND CONNECTING RODS2. Lubricate:• crankshaft pins• big end bearings• connecting rod inner surface(with the recommended lubricant)R

– 69 –ENGCRANKSHAFT AND CONNECTING RODS▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼a. Tighten the connecting rod bolts to thespecified torque.b. Tighte

– 70 –ENGTRANSMISSIONTRANSMISSIONOrder Job/Part Q’ty RemarksDisassembling the main axle assem-blyRemove the parts in the order listed.Main axle assemb

– 71 –CARBCARBURETORAIR INDUCTION SYSTEMEAS00509AIR INDUCTION SYSTEM DIAGRAMS1Reed valve2Air cut-off valve3Front cylinder head4Rear cylinder head5Air

– 72 –CARBAIR INDUCTION SYSTEMOrder Job/Part Q’ty RemarksRemoving the air induction systemRemove the parts in the order listed.Fuel tank Refer to “FUE

– 1 –SPECSPECIFICATIONSGENERAL SPECIFICATIONSItem Standard LimitModel code5VN1 (XV17A for USA)5VN2 (XV17A for California)5VN6 (XV17A for CDN)5VR1 (XV1

– 73 –CARBAIR INDUCTION SYSTEMOrder Job/Part Q’ty Remarks7 Reed valve case to front cylinder head pipe18 Rectifier/regulator coupler 1 Disconnect.9 Re

– 74 –CARBAIR INDUCTION SYSTEMOrder Job/Part Q’ty Remarks20 Air cut-off valve to reed valve cover hose121 Reed valve cover 122 Reed valve case 123 Ree

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED IN U.S.A.

XV17AS(C)/XV17ASS(C)/XV17ATS(C) WIRING DIAGRAMSbL/RBWWWWWWWWWLYBYLB/LOPB/WL/YWB/LOR/BSb/WR/BL L/BL/RL/GL/YSb L/WB/YB/LYLB/LYLOR/GRBBRBBR/WR/WRRLBBR(BL

– 2 –SPECENGINE SPECIFICATIONSENGINE SPECIFICATIONSItem Standard LimitEngineEngine type Air-cooled, 4-stroke, OHV ----Displacement 1,670 cm3----Cylind