LIT-11616-17-09
4WM-28197-E1
XV17AS(C)
XV17ASS(C)
XV17ATS(C)
SUPPLEMENTARY
SERVICE MANUAL
Page 1: ...LIT 11616 17 09 4WM 28197 E1 XV17AS C XV17ASS C XV17ATS C SUPPLEMENTARY SERVICE MANUAL...
Page 2: ...vice Manual together with the following manual XV16AL XV16ALC XV16ATL XV16ATLC SERVICE MANUAL LIT 11616 12 56 4WM 28197 E0 XV17AS C XV17ASS C XV17ATS C SUPPLEMENTARY SERVICE MANUAL 2003 by Yamaha Moto...
Page 3: ...o provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its m...
Page 4: ...f each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and c...
Page 5: ...nt B Special tool C Tightening torque D Wear limit clearance E Engine speed F Electrical data Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Engine o...
Page 6: ...L PULLEY 33 FRONT AND REAR BRAKES 35 FRONT BRAKE PADS 35 REPLACING THE FRONT BRAKE PADS 36 REAR BRAKE MASTER CYLINDER 38 FRONT BRAKE CALIPERS 40 DISASSEMBLING THE FRONT BRAKE CALIPERS 42 CHECKING THE...
Page 7: ...CARBURETOR 71 AIR INDUCTION SYSTEM 71 AIR INDUCTION SYSTEM DIAGRAMS 71 XV17AS C XV17ASS C XV17ATS C WIRING DIAGRAM...
Page 8: ...98 4 in Overall width 980 mm 38 6 in Overall height 1 140 mm 44 9 in XV17A XV17AS 1 500 mm 59 1 in XV17AT Seat height 710 mm 28 0 in Wheelbase 1 688 mm 66 5 in Minimum ground clearance 145 mm 5 71 in...
Page 9: ...e hole inside diameter 25 000 25 021 mm 0 9843 0 9851 in Camshaft cover hole inside diameter 28 000 28 021 mm 1 1024 1 1032 in Camshaft journal diameter crankcase side 24 937 24 950 mm 0 9818 0 9823 i...
Page 10: ...shaft clear ance 0 009 0 042 mm 0 0004 0 0017 in 0 08 mm 0 003 in Valve lifters Valve lifter outside diameter 22 962 22 974 mm 0 9040 0 9045 in Valve lifter case inside diameter 23 000 23 021 mm 0 905...
Page 11: ...ore clear ance 0 004 0 024 mm 0 00016 0 00094 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 2 3 8 mm 0 047 0 150 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 65 m...
Page 12: ...003 in Fuel pump Pump type Electrical Model manufacturer UC Z10C MITSUBISHI Output pressure 15 20 kPa 0 15 0 20 kgf cm2 2 13 2 84 psi Carburetor Model manufacturer quantity BSR40 MIKUNI 1 Throttle ca...
Page 13: ...aximum radial wheel runout 1 mm 0 04 in 2 mm 0 08 in XV17A for CDN Maximum lateral wheel runout 0 5 mm 0 02 in 2 mm 0 08 in XV17A for CDN Rear wheel Wheel type Cast wheel Spoke wheel XV17A for CDN Rim...
Page 14: ...36 psi Load is the total weight of the cargo rider passenger and accessories Minimum tire tread depth 1 0 mm 0 04 in Rear tire Tire type Tubeless With tube XV17A for CDN Size 150 80B16M C 71H Model ma...
Page 15: ...meter 14 0 mm 0 55 in Caliper cylinder inside diameter 27 00 mm 1 06 in and 30 20 mm 1 19 in Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position from the top of...
Page 16: ...9 SPEC CHASSIS SPECIFICATIONS Drive belt Model manufacturer UBD 0681 Drive belt slack on a sidestand 6 8 mm 0 24 0 31 in Drive belt slack on a suitable stand 7 9 mm 0 28 0 35 in Item Standard Limit...
Page 17: ...Tail brake light LED Front turn signal position light 12 V 23 W 8 W 2 Rear turn signal light 12 V 21 W 2 Licence plate light 12 V 5 W 1 Meter light 14 V 0 56 W 4 Neutral indicator light 14 V 1 12 W 1...
Page 18: ...amp Screw M4 1 4 0 4 2 9 Exhaust pipe Nut M8 4 20 2 0 14 Muffler Bolt M10 2 35 3 5 25 LT Muffler clamp Bolt M8 2 20 2 0 14 Generator rotor Bolt M12 1 80 8 0 58 E Pickup coil rotor Bolt M12 1 100 10 0...
Page 19: ...djusting nut and locknut M6 4 0 4 2 9 Engine mounting Lower front mounting bolt M12 103 10 3 74 Lower rear mounting bolt M12 88 8 8 64 Transfer gear case stay and frame M10 72 7 2 52 Muffler stay and...
Page 20: ...uum hose 7 Rectifier regulator 8 Rear brake light switch lead To engine Route the rear brake light switch lead in front of the rectifier regulator bracket on the frame To rear brake light switch Faste...
Page 21: ...Wire harness 4 Seat lock cable 5 Throttle position sensor coupler 6 Carburetor heater coupler 7 Air induction system vacuum hose 8 Fuel pump lead 9 Spark plug cap 1 0 Spark plug cap 3 A Horn B Horn l...
Page 22: ...he plastic holder Fasten the wire harness and seat lock cable to the frame with the plastic band Fasten the air induction system vacuum hose and spark plug lead 2 with the plastic holder Fasten the wi...
Page 23: ...d with the plastic holders Fasten the clutch cable with the plastic holders To air cut off valve To engine Fasten the throttle position sensor lead carbure tor heater lead and fuel pump lead to the fu...
Page 24: ...6 Tail brake light lead 7 Starter relay 8 Thermo switch 9 Starter motor lead 0 Fuel tank breather hose A Horn B Pickup coil lead C Sidestand switch lead D Horn lead E Decompression solenoid lead F Sta...
Page 25: ...e wire harness with the plastic band Fasten the wire harness and negative battery lead with the plastic holder 25 35 mm 0 98 1 38 in Fasten the tail brake light lead with the plastic holders Pass the...
Page 26: ...lead and horn lead with the plastic holder Fasten the starter motor lead sidestand switch lead and horn lead to the frame with the plastic locking ties Fasten the clutch cable to the oil delivery pipe...
Page 27: ...tle cables 8 Right handlebar switch lead 9 Main switch lead 0 Spark plug cap 4 A Spark plug cap 2 B Rear brake light switch lead C Sidestand switch coupler D Pickup coil lead E Horn leads F Starter mo...
Page 28: ...hrottle cables and fuel tank breather hose with the plastic holder Fasten the throttle cables with the plastic holder To stator coil To decompression solenoid To fuel tank To wire harness To starter r...
Page 29: ...er hose 6 Relay unit 7 Turn signal relay 8 Tail brake light and rear turn signal light sub wire harness coupler 9 Thermo switch 0 Fuse box A Fuel sender lead B Air induction system vacuum hose C Solen...
Page 30: ...r Align the yellow tape on the wire harness with the hole in battery box as shown Insert the negative battery lead coupler into the slit in the battery band Route the starter motor lead between the ba...
Page 31: ...5 Fuel tank breather hose 6 Rollover valve 7 Rollover valve to 3 way joint hose 8 Surge tank to 3 way joint hose 9 3 way joint 0 3 way joint to charcoal canister hose A Charcoal canister B Carburetor...
Page 32: ...stic holder Fasten the compensator breather hose with the plastic holder Fasten the clutch cable and rollover valve to 3 way joint hose with the plastic holders Fasten the starter motor lead and horn...
Page 33: ...OUTING 1 Carburetor to surge tank hose 2 3 way joint to surge tank hose 3 Surge tank 4 Surge tank to 3 way joint hose 5 Carburetor to charcoal canister hose 6 Solenoid valve 7 3 way joint 1 2 3 4 5 6...
Page 34: ...Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engin...
Page 35: ...ightly 14 Brake and shift pedal pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Sidestand pivot Check operation Apply lithium soap based grease all purpose grease lightly 16...
Page 36: ...if you are riding in unusually wet or dusty areas Hydraulic brake service After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels an...
Page 37: ...AND SIDE COVERS Order Job Part Q ty Remarks Removing the seats and side covers Remove the parts in the order listed 1 Rider seat 1 2 Passenger seat 1 3 Left side cover 1 4 Right side cover 1 For inst...
Page 38: ...he parts in the order listed Rider seat Refer to SEATS AND SIDE COVERS 1 Meter assembly 1 2 Meter assembly coupler 2 Disconnect 3 Fuel tank breather hose 1 4 Fuel hose 1 Disconnect NOTE Before disconn...
Page 39: ...listed NOTE Place the motorcycle on a suitable stand so that the front wheel is elevated 1 Reflector left and right 2 2 Brake caliper left and right 2 3 Wheel axle pinch bolt 1 Loosen 4 Front wheel ax...
Page 40: ...the order listed NOTE Place the motorcycle on a suitable stand so that the rear wheel is elevated Rear fender assembly Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY in chapter 4 Manual No 4WM 2...
Page 41: ...REAR WHEEL PULLEY Order Job Part Q ty Remarks 7 Right adjusting plate 1 8 Left adjusting plate 1 9 Rear wheel axle 1 10 Rear wheel 1 11 Collar left and right 2 12 Brake caliper bracket 1 For installat...
Page 42: ...Ib 7 7 Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Reflector 1 2 Brake caliper...
Page 43: ...sary to disconnect the brake hose or disas semble the brake caliper 1 Remove brake caliper bolts 1 brake caliper 2 2 Remove brake pad clips 1 brake pad pin 2 brake pad spring 3 1 1 2 3 3 Remove brake...
Page 44: ...leed screw d Install new brake pads and a new brake pad spring NOTE _ The arrow a on the brake pad spring must point in the direction of disc rotation T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb 2 1 6 Ins...
Page 45: ...he parts in the order listed Brake fluid Drain 1 Brake fluid reservoir cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake flui...
Page 46: ...39 CHAS FRONT AND REAR BRAKES Order Job Part Q ty Remarks 11 Left footrest assembly 1 12 Cotter pin 1 13 Pin 1 14 Brake master cylinder 1 For installation reverse the removal pro cedure...
Page 47: ...ers Remove the parts in the order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Reflector 1 2 Union bolt 1 Refer to DISASSEM BLING THE FRONT BRAKE CALI...
Page 48: ...calipers Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad sh...
Page 49: ...hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow c...
Page 50: ...ver the brake is disassem bled 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper pistons brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly brake...
Page 51: ...ver a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers 2 brake hose 3 union bolt 4 WARNING _ Pro...
Page 52: ...ormance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION...
Page 53: ...46 CHAS FRONT AND REAR BRAKES 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Manual No 4WM 28197 E0...
Page 54: ...sted 1 Rear view mirror left and right 2 2 Plastic clamp 4 3 Front brake light switch connector 2 Disconnect 4 Brake master cylinder holder 1 5 Brake master cylinder 1 6 Right handlebar switch 1 7 Thr...
Page 55: ...arks 12 Left handlebar switch 1 13 Handlebar grip 1 14 Clutch cable 1 Disconnect 15 Clutch lever holder 1 16 Cable guide 1 17 Upper handlebar holder 1 18 Handlebar 1 19 Lower handlebar holder 1 For in...
Page 56: ...m Remove the parts in the order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 1 Adjusting bolt 1 2 Locknut 1 3 Mud guard 1 4 Lower drive belt cover 1 5 Horn coupler 1 Disconne...
Page 57: ...50 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job Part Q ty Remarks 11 Pivot shaft 1 12 Rear shock absorber and swingarm assembly 1 For installation reverse the removal pro cedure...
Page 58: ...in the order listed 1 Self locking nut washer bolt 1 1 1 Bolt 53 mm 2 19 in 2 Self locking nut washer bolt 1 1 1 Bolt 124 mm 4 88 in 3 Connecting arm 2 4 O ring 4 5 Rear shock absorber 1 6 Spacer O r...
Page 59: ...52 CHAS REAR SHOCK ABSORBER AND SWINGARM Order Job Part Q ty Remarks 11 Spacer bearing 1 1 12 Swingarm 1 13 Dust cover 2 14 Spacer 1 15 Bearing 2 For installation reverse the removal pro cedure...
Page 60: ...order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY Rear shock absorber and swingarm assembly Refer to REAR SHOCK ABSORBER AND SWINGARM 1 Drive pulley cover bracket 1 2 Drive...
Page 61: ...to ROCKER ARMS PUSH RODS AND VALVE LIFTERS in chapter 5 Manual No 4WM 28197 E0 Decompression solenoid cover Camshaft sprocket cover 1 Cylinder head breather hose 1 2 Oil tank breather hose 1 3 Bolt 4...
Page 62: ...s in the order listed 1 Push rod 1 3 288 5 mm 11 358 in green painting 2 Push rod 2 1 290 5 mm 11 437 in yellow painting 3 Rear rocker arm base 1 Refer to REMOVING THE ROCKER ARMS PUSH RODS AND VALVE...
Page 63: ...ve the parts in the order listed 1 Push rod cover 2 2 O ring 4 3 Seal 2 4 Air filter bracket 1 5 Rear valve lifter case 1 6 Front valve lifter case 1 7 Valve lifter 4 Refer to REMOVING THE ROCKER ARMS...
Page 64: ...m base on the cylinder head b Install the push rods NOTE Be sure to correctly install the push rods between the rocker arms and valve lifters as shown The illustration is viewed from the right side of...
Page 65: ...8 70 mm 2 76 in T R Rocker arm base bolt 1 2 10 Nm 1 0 m kg 7 2 ft lb Rocker arm base bolt 3 24 Nm 2 4 m kg 17 ft lb INSTALLING THE CYLINDER HEAD COVERS The following procedure applies to both cylin d...
Page 66: ...er to CLUTCH in chapter 5 Manual No 4WM 28197 E0 Generator rotor cover Refer to GENERATOR AND STARTER CLUTCH in chapter 5 Manual No 4WM 28197 E0 1 Clutch spring plate retainer 1 2 Clutch spring plate...
Page 67: ...er spring 1 12 Clutch damper spring seat 1 13 Clutch boss 1 14 Thrust washer 1 15 Clutch housing 1 16 Circlip 1 17 Oil pump drive gear 1 18 Dowel pin 1 19 Spacer 1 20 Pickup coil rotor 1 21 Primary dr...
Page 68: ...tch boss nut 1 NOTE Install the washer on the main axle with the OUT mark facing away from the motorcy cle Lock the threads on the clutch boss nut by staking them with a drift punch at the point align...
Page 69: ...the order listed Generator cover Refer to GENERATOR AND STARTER CLUTCH in chapter 5 Manual No 4WM 28197 E0 1 Starter clutch idle gear shaft 2 1 2 Starter clutch idle gear shaft 1 1 3 Starter clutch id...
Page 70: ...pin to big end bearing clearance Out of specification Replace the big end bearings The following procedure applies to all of the connecting rods CAUTION Do not interchange the big end bearings and co...
Page 71: ...lybdenum disulfide grease Make sure the projection c on the connect ing rod faces towards the left side of the crankshaft Make sure the characters d on both the con necting rod and connecting rod cap...
Page 72: ...the bolt to the specified angle Tighten the bolt until it is at the specified angle NOTE The angle between the corners of the connect ing rod bolts is 30 h Remove the connecting rod and big end bearin...
Page 73: ...ft illustration For example if the connecting rod P1 and the crankshaft web P1 numbers are 6 and 2 respectively then the bearing size for P1 is P1 connecting rod P1 crankshaft web 6 2 4 green BIG END...
Page 74: ...e crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft and crankshaft journal bearings as a set NOTE Calculate the clearance by subtracting the crank...
Page 75: ...connecting rods and connecting rod caps Be sure to reinstall each big end bearing in its original place Make sure the projection c on the connect ing rods face towards the left side of the crankshaft...
Page 76: ...pecified angle do not loosen it 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 Tig...
Page 77: ...the parts in the order listed Main axle assembly Refer to TRANSMISSION in chapter 5 Manual No 4WM 28197 E0 1 Circlip 1 2 Washer 1 3 5th pinion gear 1 4 2nd 3rd pinion gear 1 5 Circlip 1 6 Washer 1 7...
Page 78: ...M EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cut off valve 3 Front cylinder head 4 Rear cylinder head 5 Air cleaner 6 Carburetor joint To the carburetor joint To the air cut off valve 5...
Page 79: ...Refer to FUEL TANK Fuel pump Refer to CARBURETOR in chapter 6 Manual No 4WM 28197 E0 1 Reed valve case to rear cylinder head hose 1 1 2 Reed valve case to rear cylinder head pipe 1 1 3 Reed valve case...
Page 80: ...1 8 Rectifier regulator coupler 1 Disconnect 9 Rectifier regulator 1 10 Air filter bracket 1 11 Air filter 1 12 Air filter cover 1 13 Air filter hose 1 14 Air cut off valve to air filter hose 1 15 Pl...
Page 81: ...Order Job Part Q ty Remarks 20 Air cut off valve to reed valve cover hose 1 21 Reed valve cover 1 22 Reed valve case 1 23 Reed valve base 1 24 Reed valve stopper 2 25 Reed valve 2 For installation re...
Page 82: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A...
Page 83: ...D E d e _ b a c U k j i h g f 7 F G H I J K L M N O P Q Z Y X W V R S T T 1 Generator 2 Rectifier regulator 3 Main switch 4 Battery 5 Main fuse 6 Starter relay 7 Starter motor 8 Backup fuse 9 Relay u...
