Yamaha XV1700P, XV1700PC. Service Manual

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CHK

ADJ

MEASURING THE COMPRESSION PRESSURE

7. Remove:

• spark plug

CAUTION:

Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.

8. Install:

• compression gauge set 14/18 mm

• compression gauge adapter 12 mm

Compression gauge set 14/18 mm

YU-33223

Compression gauge adapter
12 mm

YU-33223-3

9. Measure:

• compression pressure

Out of specification

→

Refer to steps (c)

and (d).

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a. Set the main switch to “ON”.
b. With the throttle wide open, crank the

engine until the reading on the compression
gauge stabilizes.

WARNING

To prevent sparking, ground all spark plug
leads before cranking the engine.

NOTE:

The difference in compression pressure
between cylinders should not exceed 100 kPa
(1 kg/cm

, 14 psi).

Compression pressure (at sea
level)

Minimum

1,040 kPa
(10.4 kg/cm

, 148 psi)

Standard

1,200 kPa
(12.0 kg/cm

, 171 psi)

Maximum

1,340 kPa
(13.4 kg/cm

, 191psi)

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MEASURING THE COMPRESSION PRESSURE

c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.

d. Carbon deposits

→

Eliminate.

e. If the compression pressure is below the

minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.

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10.Install:

• spark plug

11.Connect:

• spark plug cap

12.Remove:

• camshaft sprocket cover

Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS” in chapter 5.

13.Install:

• decompression solenoid

Refer to “CAMSHAFTS” in chapter 5.

• camshaft sprocket cover

Refer to “ROCKER ARMS, PUSH RODS
AND VALVE LIFTERS” in chapter 5.

14.Install:

• silencer air filter case

Refer to “SILENCER AIR FILTER CASE”.

• air filter case

Refer to “AIR FILTER CASE”.

• fuel tank

Refer to “FUEL TANK”.

• seat

Refer to “SEAT AND SIDE COVERS”.

Compression pressure

(with oil applied into the cylinder)

Reading

Diagnosis

Higher than
without oil

Piston ring(s) wear
or damage

→

Repair.

Same as without
oil

Piston, valves, cyl-
inder head gasket
or piston possibly
defective

→

Repair.

18 Nm (1.8 m • kg, 13 ft • lb)

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CHECKING THE ENGINE OIL LEVEL

EAS00071

CHECKING THE ENGINE OIL LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.

2. Start the engine, warm it up for several min-

utes, and then turn it off.

3. Remove:

• seat

Refer to “SEAT AND SIDE COVERS”.

4. Remove:

• dipstick

5. Check:

• engine oil level

The engine oil level should be between the
minimum level mark

and maximum level

mark

Below the minimum level mark

→

Add the

recommended engine oil to the proper level.

NOTE:

Do not screw the dipstick in when inspecting
the oil level.

CAUTION:

• Engine oil also lubricates the clutch and

the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives.

• Do not allow foreign materials to enter the

crankcase.

NOTE:

• API Service “SE”, “SF” and “SG” type or

equivalent (e.g., “SF-SE”, “SF-SE-CC”, “SF-
SE-SD”).

• Before checking the engine oil level, wait a

few minutes until the oil has settled.

Recommended oil

Yamalube 4 (20W40) or
SAE 20W40 type SE motor oil

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CHECKING THE ENGINE OIL LEVEL/

CHANGING THE ENGINE OIL

6. Install:

• dipstick

7. Start the engine, warm it up for several min-

utes, and then turn it off.

8. Check the engine oil level again.

NOTE:

Before checking the engine oil level, wait a few
minutes until the oil has settled.

9. Install:

• seat

Refer to “SEAT AND SIDE COVERS”.

EAS00073

CHANGING THE ENGINE OIL

1. Start the engine, warm it up for several min-

utes, and then turn it off.

2. Place a container under the engine oil drain

bolt.

3. Remove:

• dipstick

• engine oil drain bolt (oil tank)

• engine oil drain bolt (engine)

4. Drain:

• engine oil

(completely from the oil tank and crank-
case)

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CHANGING THE ENGINE OIL

5. If the oil filter cartridge is also to be

replaced, perform the following procedure.

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a. Remove the oil filter cartridge

with an oil

filter wrench

b. Lubricate the O-ring

of the new oil filter

cartridge with a thin coat of engine oil.

CAUTION:

Make sure the O-ring

is positioned cor-

rectly in the groove of the oil filter car-
tridge.

c. Tighten the new oil filter cartridge to specifi-

cation with an oil filter wrench.

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Oil filter wrench

YU-38411

Oil filter cartridge

17 Nm (1.7 m • kg, 12 ft • lb)

6. Check:

• engine oil drain bolt gasket

Damage

→

Replace.

7. Install:

• engine oil drain bolts

(along with the gasket)

43 Nm (4.3 m • kg, 31 ft • lb)

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CHANGING THE ENGINE OIL

8. Fill:

• oil tank

(with the specified amount of the recom-
mended engine oil)

NOTE:

• Pour the engine oil in several stages.
• First, pour in 2.5 L of oil and then start the

engine and rev it 3 to 5 times. Stop the
engine, and then pour in the remainder of the
specified amount.

CAUTION:

When starting the engine make sure the
dipstick is securely fitted into the oil tank.

Quantity

Total amount

5.0 L (4.40 Imp qt, 5.29 US qt)

Without oil filter cartridge
replacement

3.7 L (3.26 Imp qt, 3.91 US qt)

With oil filter cartridge
replacement

4.1 L (3.61 Imp qt, 4.33 US qt)

9. Fill: (when engine disassembly)

• crankcase and oil tank

NOTE:

After the engine has been disassembled, pour
the specified amount of engine oil into the
crankcase and the oil tank. When pouring
engine oil into the crankcase, pour it into the
hole of the removed bolt

Quantity

Total amount

5.0 L (4.40 Imp qt, 5.29 US qt)

Oil tank

3.0 L (2.64 Imp qt, 3.17 US qt)

Crankcase

2.0 L (1.76 Imp qt, 2.11 US qt)

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CHANGING THE ENGINE OIL

10.Install:

• dipstick

11.Start the engine, warm it up for several min-

utes, and then turn it off.

12.Check:

• engine

(for engine oil leaks)

13.Check:

• engine oil level

Refer to “CHECKING THE ENGINE OIL
LEVEL”.

14.Check:

• engine oil pressure

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a. Slightly loosen the oil gallery bolt

b. Start the engine and keep it idling until

engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.

c. Check the engine oil passages, the oil filter

cartridge and the oil pump for damage or
leakage. Refer to “ENGINE OIL PUMP” in
chapter 5.

d. Start the engine after solving the problem(s)

and check the engine oil pressure again.

e. Tighten the oil gallery bolt to specification.

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Oil gallery bolt

21 Nm (2.1 m • kg, 15 ft • lb)

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MEASURING THE ENGINE OIL PRESSURE

EAS00077

MEASURING THE ENGINE OIL PRESSURE

1. Check:

• engine oil level

Below the minimum level mark

→

Add the

recommended engine oil to the proper level.

2. Start the engine, warm it up for several min-

utes, and then turn it off.

CAUTION:

When the engine is cold, the engine oil will
have a higher viscosity, causing the engine
oil pressure to increase. Therefore, be sure
to measure the engine oil pressure after
warming up the engine.

3. Remove:

• oil gallery bolt

WARNING

The engine, muffler and engine oil are
extremely hot.

4. Install:

• oil pressure gauge

• oil pressure adaptor E

Pressure gauge

YU-03153

Oil pressure adaptor E

YM-03129

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5. Measure:

• engine oil pressure

(at the following conditions)

6. Install:

• oil gallery bolt

Engine oil pressure

40 ~ 80 kPa
(0.4 ~ 0.8 kg/cm

5.688 ~ 11.376 psi)

Engine speed

Approx. 900 r/min

Engine oil temperature

70 ~ 90 °C (158 ~ 194 °F)

Engine oil pressure

Possible causes

Below specifica-
tion

• Faulty oil pump
• Clogged oil filter
• Leaking oil pas-

sage

• Broken or dam-

aged oil seal

Above specifica-
tion

• Faulty oil filter
• Oil viscosity too

high

20 Nm (2.0 m • kg, 14 ft • lb)

CHECKING THE TRANSFER GEAR OIL
LEVEL

1. Stand the motorcycle on a level surface.

NOTE:

• Place the motorcycle on a suitable stand.
• Make sure the motorcycle is upright.

2. Remove:

• muffler
• rear exhaust pipe
• front exhaust pipe

Refer to “ENGINE” in chapter 5.

3. Remove:

• checking bolt

MEASURING THE ENGINE OIL PRESSURE/

CHECKING THE TRANSFER GEAR OIL LEVEL

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4. Check:

• transfer gear oil level

The transfer gear oil level should be up to
the brim

of the hole.

Below the brim

→

Add the recommended

transfer gear oil to the proper level.

CAUTION:

Do not allow foreign materials to enter the
transfer case.

Recommended oil

SAE80API “GL-4” Hypoid gear
oil

5. Install:

• checking bolt

6. Install:

• front exhaust pipe
• rear exhaust pipe
• muffler

Refer to “ENGINE” in chapter 5.

8 Nm (0.8 m • kg, 5.8 ft • lb)

CHANGING THE TRANSFER GEAR OIL

1. Remove:

• muffler
• rear exhaust pipe
• front exhaust pipe

Refer to “ENGINE” in chapter 5.

2. Place a container under the transfer gear oil

drain bolt.

3. Remove:

• straight plug

• transfer gear oil drain bolt

4. Drain:

• transfer gear oil

(completely from the transfer gear case)

5. Check:

• transfer gear oil drain bolt gasket

Damage

→

Replace.

CHECKING THE TRANSFER GEAR OIL LEVEL/

CHANGING THE TRANSFER GEAR OIL

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CHECKING THE TRANSFER GEAR OIL LEVEL

6. Install:

• transfer gear oil drain bolt

18 Nm (1.8 m • kg, 13 ft • lb)

7. Fill:

• transfer gear case

(with the specified amount of the recom-
mended transfer gear oil)

8. Install:

• straight plug

9. Check:

• transfer gear oil level

Refer to “CHECKING THE TRANSFER
GEAR OIL LEVEL”.

10.Install:

• front exhaust pipe
• rear exhaust pipe
• muffler

Refer to “ENGINE” in chapter 5.

Quantity

Total amount

0.49 L (0.43 Imp qt, 0.52 US qt)

Periodic oil replacement

0.4 L (0.35 Imp qt, 0.42 US qt)

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ADJUSTING THE CLUTCH CABLE FREE PLAY

EAS00078

ADJUSTING THE CLUTCH CABLE FREE
PLAY

1. Check:

• clutch cable free play

Out of specification

→

Adjust.

2. Adjust:

• clutch cable free play

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Handlebar side

a. Pull the boot

off.

b. Loosen the locknut

c. Turn the adjusting bolt

in direction

until the specified clutch cable free play

is obtained.

d. Tighten the locknut.

NOTE:

If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable,
use the adjusting nut on the engine side.

e. Pull the boot

in.

Engine side

a. Loosen the locknut

b. Turn the adjusting bolt

in direction

until the specified clutch cable free play

is obtained.

c. Tighten the locknut.

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Clutch cable free play (at the end
of the clutch lever)

10 ~ 15 mm (0.39 ~ 0.59 in)

Direction

Clutch cable free play is
increased.

Direction

Clutch cable free play is
decreased.

Direction

Clutch cable free play is
increased.

Direction

Clutch cable free play is
decreased.

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CLEANING THE AIR FILTER ELEMENTS

EAS00088

CLEANING THE AIR FILTER ELEMENTS

The following procedure applies to both air fil-
ter elements.
1. Remove:

• seat

Refer to “SEAT AND SIDE COVERS”.

• fuel tank

Refer to “FUEL TANK”.

• air filter case

Refer to “AIR FILTER CASE”.

2. Remove:

• silencer air filter case cover

• silencer air filter element

Refer to “SILENCER AIR FILTER CASE”.

• air filter case cover

• air filter element

Refer to “AIR FILTER CASE”.

3. Check:

• air filter element

Damage

→

Replace.

4. Install:

• air filter element
• air filter case cover

Refer to “AIR FILTER CASE”.

• silencer air filter element
• silencer air filter case cover

Refer to “SILENCER AIR FILTER CASE”.

CAUTION:

Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the throttle body tuning, leading to poor
engine performance and possible overheat-
ing.

5. Install:

• air filter case

Refer to “AIR FILTER CASE”.

• fuel tank

Refer to “FUEL TANK”.

• seat

Refer to “SEAT AND SIDE COVERS”.

3 - 37

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CHECKING THE THROTTLE BODY JOINTS/

CHECKING THE FUEL HOSES

EAS00094

CHECKING THE THROTTLE BODY JOINTS

The following procedure applies to all of the
throttle body joint.
1. Remove:

• seat

Refer to “SEAT AND SIDE COVERS”.

• fuel tank

Refer to “FUEL TANK”.

• air filter case

Refer to “AIR FILTER CASE”.

• silencer air filter case

Refer to “SILENCER AIR FILTER CASE”.

2. Check:

• throttle body joint

Cracks/damage

→

Replace.

3. Install:

• silencer air filter case

Refer to “SILENCER AIR FILTER CASE”.

• air filter case

Refer to “AIR FILTER CASE”.

• fuel tank

Refer to “FUEL TANK”.

• seat

Refer to “SEAT AND SIDE COVERS”.

EAS00096

CHECKING THE FUEL HOSES

The following procedure applies to all of the
fuel hoses.
1. Remove:

• air induction system cover

Refer to “FUEL TANK”.

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CHECKING THE FUEL HOSES/

CHECKING THE CYLINDER HEAD BREATHER HOSE AND OIL TANK

BREATHER HOSE

2. Check:

• fuel hose

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

3. Install:

• air induction system cover

Refer to “FUEL TANK”.

EAS00098

CHECKING THE CYLINDER HEAD
BREATHER HOSE AND OIL TANK
BREATHER HOSE

1. Remove:

• seat

Refer to “SEAT AND SIDE COVERS”.

• fuel tank

Refer to “FUEL TANK”.

• air filter case

Refer to “AIR FILTER CASE”.

• silencer air filter case

Refer to “SILENCER AIR FILTER CASE”.

2. Check:

• oil tank breather hose

• cylinder head breather hose

Cracks/damage

→

Replace.

Loose connection

→

Connect properly.

CAUTION:

Make sure the breather hoses are routed
correctly.

3. Install:

• silencer air filter case

Refer to “SILENCER AIR FILTER CASE”.

• air filter case

Refer to “AIR FILTER CASE”.

• fuel tank

Refer to “FUEL TANK”.

• seat

Refer to “SEAT AND SIDE COVERS”.

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EAS00099

CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the
exhaust pipes and gaskets.
1. Check:

• exhaust pipe

• muffler

Cracks/damage

→

Replace.

• gasket

Exhaust gas leaks

→

Replace.

2. Check:

• tightening torque

Front exhaust pipe nut

20 Nm (2.0 m • kg, 14 ft • lb)

Rear exhaust pipe bolt

24 Nm (2.4 m • kg, 17 ft • lb)

Front exhaust pipe and rear
exhaust pipe bolt

12 Nm (1.2 m • kg, 8.7 ft • lb)

Exhaust pipe and muffler bolt

12 Nm (1.2 m • kg, 8.7 ft • lb)

Muffler and muffler bracket bolt

53 Nm (5.3 m • kg, 38 ft • lb)

Muffler and muffler bracket bolts

20 Nm (2.0 m • kg, 14 ft • lb)

CHECKING THE EXHAUST SYSTEM

Yamaha XV1700P, XV1700PC. Service Manual - part 9