Yamaha XV1700PCR Road Star Warrior Owner'S Manual Download Page 51

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PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance ..........................................6-1

Owner’s tool kit ....................................................6-2

Periodic maintenance chart for the emission

control system ...................................................6-3

General maintenance and lubrication chart .........6-4

Checking the spark plugs ....................................6-7

Canister (for California only) ................................6-8

Engine oil and oil filter cartridge ..........................6-9

Transfer case oil .................................................6-13

Replacing the air filter elements ........................6-13

Adjusting the throttle cable free play ..................6-18

Adjusting the valve clearance ............................6-19

Tires ...................................................................6-19

Cast wheels .......................................................6-22

Accessories and replacement parts ..................6-23

Adjusting the clutch lever free play ....................6-23

Adjusting the brake lever free play .....................6-24

Adjusting the brake pedal position .....................6-25

Adjusting the rear brake light switch ..................6-25

Checking the front and rear brake pads .............6-26

Checking the brake fluid level ............................6-27

Changing the brake fluid ....................................6-28

Drive belt slack .................................................. 6-29

Checking and lubricating the cables ................. 6-31

Checking and lubricating the throttle grip and

cable ............................................................... 6-31

Checking and lubricating the brake and

shift pedals ...................................................... 6-31

Checking and lubricating the brake and

clutch levers .................................................... 6-32

Checking and lubricating the sidestand ............ 6-33

Lubricating the rear suspension ........................ 6-33

Checking the front fork ...................................... 6-33

Checking the steering ....................................... 6-34

Checking the wheel bearings ............................ 6-35

Battery ............................................................... 6-35

Replacing the fuses .......................................... 6-37

Replacing the headlight bulb ............................. 6-38

Tail/brake light ................................................... 6-40

Replacing a turn signal light bulb ...................... 6-40

Replacing a license plate light bulb ................... 6-41

Supporting the motorcycle ................................ 6-42

Troubleshooting ................................................. 6-42

Troubleshooting chart ........................................ 6-43

Summary of Contents for XV1700PCR Road Star Warrior

Page 1: ...5PX 28199 11 LIT 11626 16 36 XV1700PCR XV1700PCRC OWNER S MANUAL...

Page 2: ...EAU03438...

Page 3: ...asic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorc...

Page 4: ...precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE _ This manual should be considered a permanent part of...

Page 5: ...OTOR CYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNI...

Page 6: ...R XV1700PCRC OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition June 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporati...

Page 7: ...RIPTION 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICAT...

Page 8: ......

Page 9: ...SAFETY INFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7...

Page 10: ...N MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger...

Page 11: ...CESSIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning...

Page 12: ...tem during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Mod...

Page 13: ...fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically d...

Page 14: ...may limit control ability therefore such accessories are not recommended 2 Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical...

Page 15: ...source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean...

Page 16: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle...

Page 17: ...SAFETY INFORMATION 1 1 8 1 California only 2 3 4 5 California only...

Page 18: ......

Page 19: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3...

Page 20: ...1 2 EAU00026 2 DESCRIPTION Left view 1 Engine oil drain bolt crankcase page 6 11 2 Shift pedal page 3 7 3 Fuel tank cap page 3 9 4 Helmet holder page 3 11 5 Fuses page 6 37 6 Owner s tool kit page 6...

Page 21: ...rk spring preload adjusting bolt page 3 12 10 Engine oil filter cartridge page 6 11 11 Brake pedal page 3 8 12 Engine oil drain bolt oil tank page 6 10 13 Shock absorber assembly spring preload adjust...

Page 22: ...ments 1 Clutch lever page 3 7 2 Left handlebar switches page 3 6 3 Speedometer page 3 3 4 Tachometer unit page 3 4 5 Main switch steering lock page 3 1 6 Right handlebar switches page 3 7 7 Throttle g...

Page 23: ...edometer 3 3 Tachometer unit 3 4 Handlebar switches 3 6 Clutch lever 3 7 Shift pedal 3 7 Brake lever 3 8 Brake pedal 3 8 Fuel tank cap 3 9 Fuel 3 9 Seat 3 11 Helmet holder 3 11 Adjusting the front for...

Page 24: ...art ed The key cannot be removed NOTE _ The headlight comes on automatically when the engine is started and stays on until the key is turned to OFF even if the engine stalls _ EAU00038 OFF All electri...

Page 25: ...lights and The corresponding indicator light flash es when the turn signal switch is pushed to the left or right EAU04878 Fuel level warning light This warning light comes on when the fuel level drop...

Page 26: ...ng the key to ON If the warning light does not come on for a few seconds then go off have a Yamaha dealer check the elec trical circuit EAU00061 Neutral indicator light This indicator light comes on w...

Page 27: ...l warning light came on a meter lighting control a clock a self diagnosis device NOTE _ Be sure to turn the key to ON before using the SELECT and RESET buttons To switch the odometer the trip meters a...

Page 28: ...after refueling and traveling 3 mi 5 km Meter lighting control mode 1 Turn the key to OFF 2 Push and hold the SELECT but ton 3 Turn the key to ON and then after five seconds release the SELECT button...

Page 29: ...beam and to for the low beam EAU04218 Turn signal switch To signal a right hand turn push this switch to To signal a left hand turn push this switch to When released the switch returns to the cen ter...

Page 30: ...left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch o...

Page 31: ...lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the...

Page 32: ...then close the lock cover NOTE _ The fuel tank cap cannot be closed un less the key is in the lock In addition the key cannot be removed if the cap is not properly closed and locked _ EWA00025 WARNIN...

Page 33: ...esearch octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenanc...

Page 34: ...he projection on the rear of the seat into the seat holder as shown 2 Push the front of the seat down to lock it in place 3 Remove the key NOTE _ Make sure that the seat is properly se cured before ri...

Page 35: ...00035 WARNING _ Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result _ Adjust the spring preload as follows To increase the spring preload and thereby harden...

Page 36: ...e suspen sion turn the adjusting nut in di rection a To decrease the spring preload and thereby soften the suspension turn the adjusting nut in direction b NOTE _ Use the special wrench included in th...

Page 37: ...rce adjusting mecha nism may not exactly match the above specifications due to small differences in production the actual number of clicks always represents the entire ad justing range To obtain a pre...

Page 38: ...destand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the motorcycle upright NOTE _ The built in sidestand switch is part of the i...

Page 39: ...he side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down It cuts the running engine...

Page 40: ...he sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clut...

Page 41: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1...

Page 42: ...sary add recommended oil to specified level Check vehicle for oil leakage 6 9 6 10 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust...

Page 43: ...tire condition and tread depth Check air pressure Correct if necessary 6 19 6 22 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and...

Page 44: ......

Page 45: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Shifting 5 3 Engine break in 5 5 Parking 5 5...

Page 46: ...ing in a possible loss of control _ EAU00376 CAUTION _ Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not...

Page 47: ...utral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit _ 3 Start the engine by pushing the start switch NOTE _ If the engine fails to start release the start s...

Page 48: ...n Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting _ EAU02988 To start out and acc...

Page 49: ...ch lever in and use the brakes to stop the motorcycle 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EA...

Page 50: ...ed operation above 3 500 r min ECA00026 CAUTION _ After 600 mi 1 000 km of operation the engine oil and transfer case oil must be changed and the oil filter cartridge replaced _ 1 000 mi 1 600 km and...

Page 51: ...n 6 25 Adjusting the rear brake light switch 6 25 Checking the front and rear brake pads 6 26 Checking the brake fluid level 6 27 Changing the brake fluid 6 28 Drive belt slack 6 29 Checking and lubri...

Page 52: ...EW000060 WARNING _ If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you _ EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR...

Page 53: ...formance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE _ If you do not have the tool...

Page 54: ...clean Replace at 8 000 mi 13 000 km or 12 months and thereafter every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace...

Page 55: ...ssary 4 Front brake Check operation and fluid leakage See NOTE page 6 6 Correct if necessary Replace brake fluid 5 Rear brake Check operation and fluid leakage See NOTE page 6 6 Correct if necessary R...

Page 56: ...Lithium soap based grease all purpose grease 14 Sidestand switch Check and clean or replace if necessary 15 Front fork Check operation and for leakage 16 Steering bearings Check bearing assembly for l...

Page 57: ...nders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and...

Page 58: ...ally and all spark plugs installed in the engine should have the same color If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problem...

Page 59: ...ed to the speci fied torque as soon as possible _ EAU00499 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before opera...

Page 60: ...rm it up until the engine oil has reached a nor mal temperature of 140 F 60 C let it continue to idle for ten sec onds and then turn the engine off NOTE _ To achieve the proper engine oil tem perature...

Page 61: ...s se curely tightened otherwise oil may seep out when the engine is run ning _ To change the engine oil with or without oil filter cartridge replace ment 1 Remove the seat See page 3 11 for seat remov...

Page 62: ...om the crankcase 7 Remove the oil filter cartridge with an oil filter wrench NOTE _ An oil filter wrench is available at a Yamaha dealer _ 8 Apply a thin coat of engine oil to the O ring of the new oi...

Page 63: ...mical additives Do not use oils with a diesel speci fication of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no forei...

Page 64: ...which is locat ed in the air filter case the other is lo cated in the silencer case The air filter elements should be re placed at the intervals specified in the periodic maintenance and lubrication c...

Page 65: ...nuts c Disconnect fuel hose B from the joint as shown ECA00121 CAUTION _ Place a towel or cloth under the fuel hose joints when discon necting hoses A and B to pre vent fuel from spilling onto the ve...

Page 66: ...the hoses as shown and then remove the fuel tank by pull ing it upward 4 Remove the air filter case bolts 5 Loosen the air filter joint clamp screw and then pull off the air filter case 1 Hose 2 1 Ai...

Page 67: ...should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 9 Remove the clamp from the check hose and then remove the plug...

Page 68: ...t have a Yamaha dealer replace the hose other wise fuel may leak Make sure that the fuel hoses are properly connected and routed and not pinched _ b Install the nuts c Connect fuel hose A 15 Install t...

Page 69: ...ilter ele ment installed otherwise the pistons and or cylinders may become excessively worn _ 5 Install the silencer air filter case cover by installing the screws 6 Install the fuel tank See step 14...

Page 70: ...cked and if necessary adjusted before each ride EW000082 WARNING _ The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature...

Page 71: ...the maxi mum load of the motorcycle Opera tion of an overloaded motorcycle could cause tire damage an acci dent or even injury _ Tire inspection Always check the tires before operating the motorcycle...

Page 72: ...ays make sure that the valve caps are securely installed to prevent air pressure leakage Use only the tire valves and valve cores listed below to avoid tire deflation during a high speed ride _ CE 10E...

Page 73: ...s adjust the tire air pres sure according to the operating conditions _ EAU03773 Cast wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points re...

Page 74: ...a approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yama...

Page 75: ...cally check the brake lever free play and if necessary adjust it as fol lows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rection a To...

Page 76: ...torcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident _ EAU00713 Adjusting the rear brake light switch The rear brake light swi...

Page 77: ...groove which allows you to check the brake pad wear with out having to disassemble the brake To check the brake pad wear check the wear indicator groove If a brake pad has worn to the point that the w...

Page 78: ...lenish if necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake fluid level is low be sure to check the brake pads for wear and the brake system for...

Page 79: ...l for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03976 Changing the brake fluid Have a Yamaha dealer change...

Page 80: ...k hole are 0 2 in 5 mm apart _ 3 Note the position of the drive belt with a force of 10 lbf 4 5 kgf 45 N applied to the belt with a belt ten sion gauge as shown NOTE _ A belt tension gauge is availabl...

Page 81: ...f the swingarm make sure that both belt pullers are in the same posi tion for proper wheel alignment _ ECA00025 CAUTION _ Improper drive belt slack will over load the engine Keep the drive belt slack...

Page 82: ...ement Replace damaged ca bles as soon as possible to prevent unsafe conditions _ EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked befo...

Page 83: ...hecking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended...

Page 84: ...g points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart EAU02939 Checking the front fork The condition and operation of the fro...

Page 85: ...er check or re pair it _ EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified...

Page 86: ...seals as this would permanent ly damage the battery _ EW000116 WARNING _ Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin e...

Page 87: ...If the battery will be stored for more than two months check it at least once a month and fully charge it if necessary 3 Fully charge the battery before in stallation 4 After installation make sure t...

Page 88: ...n off the electrical circuit in question 3 Remove the blown fuse and then install a new fuse of the specified amperage 1 Battery band 2 Battery cover 1 Headlight fuse 2 Signaling system fuse 3 Ignitio...

Page 89: ...vice operates 5 If the fuse immediately blows again have a Yamaha dealer check the electrical system 6 Install the battery cover and then hook the battery band onto the holder EAU04189 Replacing the h...

Page 90: ...0105 CAUTION _ Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fect...

Page 91: ...Replacing a turn signal light bulb 1 Remove the turn signal lens by re moving the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the sock...

Page 92: ...Remove the defective bulb by pull ing it out 4 Insert a new bulb into the socket 5 Install the license plate light lens by installing the washers and the nuts 6 Install the license plate light unit by...

Page 93: ...wheel off the ground by using a motorcycle stand or if a motor cycle stand is not available by placing a jack either under each side of the frame in front of the rear wheel or under each side of the s...

Page 94: ...o compression Check the ignition Have a Yamaha dealer check the vehicle Remove the spark plugs and check the electrodes 3 Ignition Wipe off with a dry cloth and correct the spark plug gaps or replace...

Page 95: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4...

Page 96: ...s are tightly in stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets the drive belt and whe...

Page 97: ...washing _ After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubb...

Page 98: ...waxes many of which contain abrasives that may mar the paint or protective finish 7 Let the motorcycle dry completely before storing or covering it EWA00001 WARNING _ Make sure that there is no oil o...

Page 99: ...dd fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 3 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove t...

Page 100: ...the wheels a little every month in order to prevent the tires from becoming degraded in one spot 6 Cover the muffler outlet with a plastic bag to prevent moisture from entering it 7 Remove the battery...

Page 101: ...SPECIFICATIONS 8 Specifications 8 1...

Page 102: ...113 mm Compression ratio 8 36 1 Starting system Electric starter Lubrication system Dry sump Engine oil Type YAMALUBE 4 20W 40 or SAE 20W 40 Recommended engine oil classification API Service SE SF SG...

Page 103: ...K DPR7EA 9 or DENSO X22EPR U9 Gap 0 03 0 04 in 0 8 0 9 mm Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 532 Secondary reduction system Belt dr...

Page 104: ...otal weight of rider passenger cargo and accessories Wheels Front Type Cast wheel Size 18 MT 3 50 18 M C MT 3 50 Rear Type Cast wheel Size 17 MT 6 00 17 M C MT 6 00 Brakes Front Type Dual disc brake O...

Page 105: ...ight 12 V 23 8 W 2 Rear turn signal light 12 V 23 W 2 Meter lighting LED Neutral indicator light LED High beam indicator light LED Turn signal indicator light LED 2 Fuel level warning light LED Engine...

Page 106: ......

Page 107: ...tion number 9 1 Vehicle identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO M...

Page 108: ...LABEL INFORMATION CA 01E EAU01041 Key identification number The key identification number is stamped into the key tag Record this number in the space provided and use it for reference when ordering a...

Page 109: ...label is affixed to the frame under the seat See page 3 11 for seat removal and installation procedures Record the information on this label in the space provided This information will be needed when...

Page 110: ...ints it may open an investigation and if it finds that a safety defect exists in a group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual proble...

Page 111: ...ed into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of desi...

Page 112: ...ranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing deale...

Page 113: ...6 9 28 000 mi 43 000 km or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer na...

Page 114: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY...

Page 115: ...CONSUMER INFORMATION 9 8 9...

Page 116: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S...

Page 117: ...CONSUMER INFORMATION 9 10 9...

Page 118: ...fork checking 6 33 Fuel 3 9 Fuel level warning light 3 2 Fuel tank cap 3 9 Fuses replacing 6 37 H Handlebar switches 3 6 Headlight bulb replacing 6 38 Helmet holder 3 11 High beam indicator light 3 2...

Page 119: ...Throttle cable free play adjusting 6 18 Throttle grip and cable checking and lubricating 6 31 Tires 6 19 Tool kit 6 2 Transfer case oil 6 13 Troubleshooting 6 42 Troubleshooting chart 6 43 Turn signal...

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Page 122: ...PRINTED IN JAPAN 2002 07 0 5 2 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD...

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