Yamaha XV1700P, XV1700PC. Service Manual - part 25

5 - 118

ENG

WARNING

When the bolts are tightened more than the
specified angle, do not loosen the bolt and
then retighten it.
Replace the bolt with a new one and per-
form the procedure again.

CAUTION:

• Do not use a torque wrench to tighten the

bolt to the specified angle.

• Tighten the bolt until it is the specified

angle.

NOTE:

When using a hexagonal bolt note that the
angle from one corner to another is 60°.

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EAS00408

INSTALLING THE CRANKSHAFT

1. Install:

• generator shaft

2. Install:

• crankshaft assembly

CAUTION:

To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.

NOTE:

• Make sure that the generator shaft drive gear

teeth and generator shaft driven gear teeth
mesh correctly.

• Align the right connecting rod with the front

cylinder sleeve hole.

CRANKSHAFT AND CONNECTING RODS

5 - 119

ENG

TRANSMISSION

EAS00419

TRANSMISSION

Order

Job/Part

Q’ty

Remarks

Removing the transmission, shift
drum assembly, and shift forks

Remove the parts in the order listed.

Crankcase

Separate.
Refer to “CRANKCASE”.

Shift fork guide bar

Shift fork “L”

Shift fork “R”

Shift fork “C”

Shift drum assembly

Drive axle assembly

Main axle assembly

Spacer

For installation, reverse the removal
procedure.

5 - 120

ENG

TRANSMISSION

Order

Job/Part

Q’ty

Remarks

Disassembling the main axle
assembly

Remove the parts in the order listed.

Circlip

Washer 1

5th pinion gear

2nd/3rd pinon gear

Circlip

Washer

4th pinon gear

Main axle/1st pinon gear

For assembly, reverse the disassembly
procedure.

5 - 121

ENG

TRANSMISSION

Order

Job/Part

Q’ty

Remarks

Disassembling the drive axle
assembly

Remove the parts in the order listed.

5th wheel gear

Circlip 1

Washer

2nd wheel gear

Circlip

Washer

1st wheel gear

4th wheel gear

Circlip

Washer

3rd wheel gear

Drive axle

For assembly, reverse the disassembly
procedure.

5 - 122

ENG

TRANSMISSION

EAS00421

CHECKING THE SHIFT FORKS

The following procedure applies to all of the
shift forks.
1. Check:

• shift fork cam follower

• shift fork pawl

Bends/damage/scoring/wear

→

Replace

the shift fork.

2. Check:

• shift fork guide bar

Roll the shift fork guide bar on a flat surface.
Bends

→

Replace.

WARNING

Do not attempt to straighten a bent shift
fork guide bar.

3. Check:

• shift fork movement

(along the shift fork guide bar)
Rough movement

→

Replace the shift forks

and shift fork guide bar as a set.

5 - 123

ENG

TRANSMISSION

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:

• shift drum grooves

Damage/scratches/wear

→

Replace the

shift drum assembly.

• shift drum segment

Damage/wear

→

Replace the shift drum

assembly.

• shift drum bearing

Damage/pitting

→

Replace the shift drum

assembly.

EAS00425

CHECKING THE TRANSMISSION

1. Measure:

• main axle runout

(with a centering device and dial gauge

)

Out of specification

→

Replace the main

axle.

2. Measure:

• drive axle runout

(with a centering device and dial gauge

)

Out of specification

→

Replace the drive

axle.

Main axle runout limit

0.08 mm (0.003 in)

Drive axle runout limit

0.08 mm (0.003 in)

3. Check:

• transmission gears

Blue discoloration/pitting/wear

→

Replace

the defective gear(s).

• transmission gear dogs

Cracks/damage/rounded edges

→

Replace

the defective gear(s).

5 - 124

ENG

TRANSMISSION

4. Check:

• transmission gear engagement

(each pinion gear to its respective wheel
gear)
Incorrect

→

Reassemble the transmission

axle assemblies.

5. Check:

• transmission gear movement

Rough movement

→

Replace the defective

part(s).

6. Check:

• circlips

Bends/damage/looseness

→

Replace.

EAS00428

INSTALLING THE TRANSMISSION

1. Install:

• main axle assembly

• drive axle assembly

• O-ring
• spacer

EAS00426

INSTALLING THE SHIFT FORKS AND
SHIFT DRUM ASSEMBLY

1. Install:

• shift fork “R”
• shift fork “C”
• shift fork “L”
• shift drum assembly

• shift fork guide bars

NOTE:

The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.

5 - 125

ENG

TRANSMISSION

2. Check:

• transmission

Rough movement

→

Repair.

NOTE:

Oil each gear, shaft, and bearing thoroughly.

6 - 1

FUEL INJECTION SYSTEM

Linear control valve

Intake air pressure sensor 2

Intake air temperature sensor

Intake air pressure sensor 1

Engine temperature sensor

Atmospheric pressure sensor

Throttle position sensor

Spark plug

Relay unit

ECU

Battery

Fuel pump

Lean angle cut-off switch

Oil temperature sensor

Decompression solenoid

Crankshaft position sensor

Cylinder identification sensor

Ignition coil

F E D

FUEL INJECTION SYSTEM

6 - 2

FUEL INJECTION SYSTEM

WIRING DIAGRAM

(BLACK)

(GRAY)

(BLA

CK)

B
Y
L

(BLA

CK)

(GRA

(BLA

CK)

(GRA

ARK GRA

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLUE)

B
B

(BLUE)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(BLA

CK)

(RED)

(BLUE)

(GREEN)

(RED)

(BLUE)

OFF

(BLACK)

(BLUE)

(L)

N (R)

[

]

{

}

WIREHARNESS

TAIL SUB-WIREHARNESS

(BLACK)

WIREHARNESS

INJECTION SUB-WIREHARNESS

6 - 3

FUEL INJECTION SYSTEM

Main switch

Battery

Main fuse

Fuel injection system relay

Fuel pump

Crankshaft position sensor

Throttle position sensor

Intake air pressure sensor 1

Intake air pressure sensor 2

Atmospheric pressure sensor

Cylinder identification sensor

Lean angle cut-off switch

Speed sensor

Intake air temperature sensor

Engine temperature sensor

Oil temperature sensor

ECU

Linear control valve

Cylinder #1-injector

Cylinder #2-injector

Engine stop switch

{

Ignition fuse

ECU fuse

Fuel injection system fuse

6 - 4

FUEL INJECTION SYSTEM

ECU’S SELF-DIAGNOSTIC FUNCTION

The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys-
tem is operating normally. If this function detects a malfunction in the system, it immediately oper-
ates the engine under substitute characteristics and illuminates the engine trouble warning light to
alert the rider that a malfunction has occurred in the system. Once a malfunction has been detected,
it becomes stored in the ECU memory in the form of a fault code.

ECU’s mode function

The ECU is equipped with a diagnosis mode, in addition to the normal mode in which the ECU oper-
ates normally.

Normal mode
• To check whether the warning light bulb is blown, the warning light illuminates for 1.4 seconds

after the main switch has been turned ON, and while the starter switch is being pressed.

• To inform the rider that the fuel injection stop function is active, the warning light blinks while the

start switch is being pressed to start the engine.

• If a malfunction in the system is detected by the self-diagnostic function, this mode provides an

appropriate substitute characteristic operation, and alerts the rider of the detected malfunction by
illuminating a warning light.

• After the engine has been stopped, digital numbers representing the self-diagnostic fault codes

appear on the clock LCD. Once a self-diagnostic fault code has been displayed, it remains stored
in the ECU memory until a deletion operation is performed.

Diagnosis mode
• In this mode, diagnostic codes are input into the ECU in accordance with the number of times the

start switch has been operated.

• In accordance with the diagnostic codes, the ECU displays the values received from the sensors

and actuates the actuators.

• Whether or not the system is operating normally is determined by a human operator through the

observations of the values indicated by the engine trouble warning light or the actuating conditions
of the actuators.

6 - 5

FUEL INJECTION SYSTEM

Engine trouble warning light indication and FI system operating conditions (normal mode)

Warning light

indication

ECU’s operating

condition

FI operating condition

Starting and driving

ON and OFF *1

Self-diagnostic func-
tion in operation

FI function in operation Able

Blinking *2

Warning control when
unable to start engine

Operation stopped

Unable

Continuous ON

Detecting malfunction

Gives driving instruc-
tions with substitute
characteristics in accor-
dance with the descrip-
tion of the malfunction.

Able/Unable depend-
ing on self-diagnostic
fault code

OFF *3

Possibly a blown warn-
ing light bulb or a mal-
function in power
supply system or ECU

*1
The warning light illuminates 1.4 seconds each
time the main switch is turned ON. The ECU
performs a self diagnosis during this time and
turns OFF the light thereafter.

*2
Warning control when unable to start engine
This control is effected when any one of the
conditions listed below is present and the
starter switch is turned ON:
a. Battery voltage below the specified value

(defective Fuel injection system relay,
engine stop switch turned OFF, or drained
battery)

b. One of the fault codes listed below has

been detected (self-diagnostic code 12, 19,
30, 41, or 50 is output):
(12: faulty crankshaft position sensor sig-
nal)
(19: open circuit in sidestand input line)
(30: a fall has been detected)
(41: open or short circuit in lean angle cut-
off switch)
(50: ECU memory check error)

Main switch
OFF

Main switch
ON

Light ON for
1.4 seconds

Light
OFF

Initialize

Engine trouble
warning light

6 - 6

FUEL INJECTION SYSTEM

*3
Function to check for blown warning light bulb
The engine trouble warning light illuminates

for 1.4 seconds after the main switch has been
turned “ON” and while the starter switch is
being pressed. If the warning light does not
illuminate under these conditions, a problem
may have possibly occurred, such as a blown
warning light bulb. Therefore, take an appropri-
ate corrective action by referring to the trouble-
shooting section.

Determining the area of the malfunction through the self-diagnostic fault code number

The possible location of the system in which a problem may be occurring can be determined by
observing the self-diagnostic fault code number that appears on the tachometer and cross-referenc-
ing it on the fault code number table. When used in conjunction with the troubleshooting details, and
by checking the possible items one by one, you will be able to identify the cause of the problem in
order to carry out an accurate repair work.

Warning of the occurrence of a malfunction appears on the tachometer.

Determine the area of the problem by referring to the self-diagnostic fault code number.

Turn off the main switch.

Repair the problem area by referring to the troubleshooting details.

Turn “ON” the main switch in order to revert to normal operation, and erase the fault code from

memory. (Once a fault code is detected by the ECU, it remains stored in the ECU memory even

after the main switch has been turned “OFF”.)

6 - 7

FUEL INJECTION SYSTEM

* Table of self-diagnostic fault code numbers displayed on meter

• How to erase the self-diagnostic fault code from memory:

If the ECU detects a normal signal upon the completion of the repair of the malfunction, the self-
diagnostic fault code disappears from the meter and is replaced by the normal clock display. How-
ever, the self-diagnostic fault code of the previous malfunction remains in the ECU memory as
part of the malfunction history. To erase the self-diagnostic fault code from the malfunction history,
the operation for diagnostic code 62 must be performed in the diagnosis mode.

No.

Symptom

Able/

unable to

start

Able/

unable to

drive

No.

Symptom

Able/

unable to

start

Able/

unable to

drive

No normal signals are received
from the cylinder identification
sensor.

Able

Faulty intake air pressure sensor
pipe system 2; a hose is
detached, causing the constant
application of atmospheric pres-
sure to the sensor; or, the hose is
clogged.

Able

No normal signals are received
from the crankshaft position sen-
sor.

Unable

Oil temperature sensor - open or
short circuit detected.

Able

Intake air pressure sensor 1 -
open or short circuit detected.

Able

Engine temperature sensor -
open or short circuit detected.

Able

Faulty intake air pressure sensor
pipe system 1; a hose is
detached, causing the constant
application of atmospheric pres-
sure to the sensor; or, the hose is
clogged.

Able

Decompression thermostat -
open or short circuit detected.

Able

Throttle position sensor - open or
short circuit detected.

Able

The motorcycle has overturned.

Unable

A stuck throttle position sensor is
detected.

Able

Linear control valve - faulty valve
or motor is detected.

Able

Open circuit is detected in the
input line from the sidestand
switch to the ECU.

Unable

Decompression solenoid - open
circuit is detected.

Able

Atmospheric pressure sensor or
intake air pressure sensor
Malfunction of the atmospheric
pressure sensor in the intermedi-
ate electrical potential.
Malfunction of the intake air pres-
sure sensor in the intermediate
electrical potential.

Able

Lean angle cut-off switch - open
or short circuit detected.

Unable

Intake temperature sensor - open
or short circuit detected.

Able

No normal signals are received
from the speed sensor; or, an
open or short circuit is detected in
the neutral switch.

Able

Atmospheric pressure sensor -
open or short circuit detected.

Able

The ECU is unable to monitor the
battery voltage (an open circuit in
the line to the ECU).

Able

Intake air pressure sensor 2 -
open or short circuit detected.

Able

Faulty ECU memory. When this
malfunction is detected, the code
number might not appear on the
meter.

Unable

6 - 8

FUEL INJECTION SYSTEM

SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)

If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU
illuminates the engine trouble warning light and provides the engine with substitute characteristic
operation instructions that are appropriate for the type of the malfunction.
When an abnormal signal is received from a sensor, the ECU processes the specified values that
are programmed for every sensor, in order to provide the engine with substitute characteristics
operation instructions that enable the engine to continue to operate (or to stop its operation,
depending on circumstances).
The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed
value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions
are given in the table below.

Table of substitute characteristic operation control by self-diagnostic fault code

Code No.

Item

Fail-safe action

Able/unable to

start

Able/unable to

drive

Cylinder identification
sensor

• Continues to operate the engine based on the

results of the cylinder identification that existed up
to that point.

Able

Crankshaft position sen-
sor

• Stops the engine (by stopping the injection and

ignition).

Unable

13
14
25
26

Intake air pressure sensor
(open or short circuit)
(pipe system)

• Fixes the intake air pressure to 760 mmHg.

Able

15
16

Throttle position sensor
(open or short circuit)
(stuck)

• Fixes the throttle position sensor to fully open.

Able

Sidestand switch
(open circuit in wire to
ECU)

-- (No start)

Unable

Atmospheric pressure
sensor or intake air pres-
sure sensor

• Fixes the atmospheric correction value to 0 mmHg.

Able

Intake temperature sen-
sor

• Fixes the intake temperature to 15 °C (59 °F).

Able

Atmospheric pressure
sensor

• Fixes the atmospheric pressure to 760 mmHg.

Able

Oil temperature sensor

• Fixes the oil temperature to 80 °C (176 °F).

Able

Engine temperature sen-
sor

• Fixes the engine temperature to 140 °C (284 °F).

Able

Decompression thermo-
stat

• Electricity is not circulated to the decompression

solenoid and the thermostat is not operated.

Able

Linear control valve

Able

Decompression solenoid

Able

30
41

Lean angle cut-off switch
(latch up detected)
(open or short circuit)

• Turns OFF the fuel injection system relay of the fuel

system.

Unable

Speed sensor, neutral
switch

• Fixes the gear to the top gear.

Able

Fuel system voltage
(monitor voltage)

• Fixes the battery voltage to 12 V.

Able

ECU internal malfunction
(memory check error)

Unable

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