Yamaha XV17ASS(C) Supplementary Service Manual Download

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LIT-11616-17-09

4WM-28197-E1

XV17AS(C)

XV17ASS(C)

XV17ATS(C)

SUPPLEMENTARY

SERVICE MANUAL

Summary of Contents for XV17ASS(C)

Page 1: ...LIT 11616 17 09 4WM 28197 E1 XV17AS C XV17ASS C XV17ATS C SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ...rvice 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 Motor Corporation U S A First Edition May 2003 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in...

Page 3: ...to 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 models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable This ...

Page 4: ...of 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 clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 5: ...ant 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 oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap based grease L Molybdenum disulfide grease Symbols M to N in the exploded diagrams indicate the following M Apply lockin...

Page 6: ...EL 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 FRONT BRAKE CALIPERS 43 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 44 HANDLEBAR 47 REAR SHOCK ABSORBER AND SWINGARM 49 DRIVE BELT AND DRIVE PULLEY 53 ENGINE 54 ROCKER ARMS PUSH RODS AND VALVE...

Page 7: ...CARBURETOR 71 AIR INDUCTION SYSTEM 71 AIR INDUCTION SYSTEM DIAGRAMS 71 XV17AS C XV17ASS C XV17ATS C WIRING DIAGRAM ...

Page 8: ...m 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 Minimum turning radius 3 200 mm 126 in Weight Wet with oil and a full fuel tank 334 kg 736 lb XV17A XV17AS 349 kg 769 lb XV17AT Dry without oil and fuel 312 kg 688 lb XV17A XV17AS 327 kg 721 lb XV17...

Page 9: ...se 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 in Camshaft journal diameter camshaft cover side 27 967 27 980 mm 1 1011 1 1016 in Camshaft to crankcase clearance 0 050 0 084 mm 0 0020 0 0033 in Camshaft to camshaft cover clear ance 0 020 0 054 mm ...

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 9055 0 9063 in Valve lifter to valve lifter case clear ance 0 026 0 059 mm 0 0010 0 0023 in Valve push rods Valve push rod length 1 288 25 288 75 mm 11 348 11 368 in Valve push rod length 2 290 25 290 7...

Page 11: ...bore 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 mm 0 026 in Ring side clearance 0 03 0 08 mm 0 0012 0 0031 in 0 12 mm 0 0047 in 2nd ring Ring type Taper 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 8 mm 0...

Page 12: ...0 003 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 cable free play at the flange of the throttle grip 4 6 mm 0 16 0 24 in ID mark 5VN1 00 5VN2 10 for California Main jet 182 5 Main air jet 60 Jet needle 6HDC26 1 Needle jet X 2M Pilot air jet 1 100 Pilo...

Page 13: ...Maximum 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 Size 16M C MT3 50 Material Aluminum Steel XV17A for CDN Wheel travel 110 mm 4 33 in Wheel runout Maximum radial wheel runout 1 mm 0 04 in 2 mm 0 08 in XV17A for CDN Maximum lateral wheel runout 0 5 ...

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 manufacturer USA CDN G702 N BRIDGESTONE XV17A XV17AS G702 BRIDGESTONE XV17AT G702 BRIDGESTONE XV17A XV17AT D404 DUNLOP XV17A G702 N BRIDGESTONE XV17AS Tire pressure cold 0 90 kg 0 198 lb 250 kPa 2 5 kg...

Page 15: ...ameter 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 the brake pedal to the bottom of the rider footrest board 100 mm 3 9 in Recommended fluid DOT 4 Brake discs Diameter thickness 320 7 mm 12 6 0 28 in Minimum thickness 6 5 mm 0 26 in Maximum deflecti...

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: ...1 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 Turn signal indicator light 14 V 1 12 W 1 High beam indicator light 14 V 1 12 W 1 Fuel level indicator light LED Engine trouble indicator light LED Turn signal relay Relay type Semi transistor Model...

Page 18: ...lamp 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 72 Clutch boss Nut M20 1 105 10 5 75 Stake Pull lever Bolt M6 1 12 1 2 8 7 Middle drive gear Nut M22 1 100 10 0 72 Use a lock washer Drive pulley case Bolt M10 3 50 5 0 36 Drive pulley case Bolt M8 4...

Page 19: ...adjusting 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 frame M10 53 5 3 38 Fuel sender and fuel tank M6 8 0 8 5 8 Rear fender side mold and rear fender stay M8 28 2 8 20 Sidestand bolt M10 89 8 9 64 Sidestand nut M10 32 3 2 23 Rear brake fluid reservoir ...

Page 20: ...7 Rectifier regulator 8 Rear brake light switch lead È To engine É Route the rear brake light switch lead in front of the rectifier regulator bracket on the frame Ê To rear brake light switch Ë Fasten the rear brake light switch lead with the plastic holder Ì Fasten the rear brake light switch lead and recti fier regulator lead with the plastic locking tie 5 4 3 2 1 3 8 7 6 3 Ë Ê È É Ì ...

Page 21: ...eat 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 lead C Starter motor lead D Clutch cable B A B Ê È Ò È Ò Ñ Ñ Ó Ô Ð É Ë Ì Í Î Ï 4 1 D C 8 6 5 B A 0 2 3 5 6 7 8 9 Õ Ö A ...

Page 22: ... Fasten the wire harness and seat lock cable to the frame with the plastic band Ì Fasten the air induction system vacuum hose and spark plug lead 2 with the plastic holder Í Fasten the wire harness seat lock cable spark plug lead 1 and spark plug lead 2 to the engine bracket with the plastic band Î Fasten the spark plug lead 1 and spark plug lead 2 with the plastic holder Ï Fasten the wire harness...

Page 23: ...olders Ò Fasten the clutch cable with the plastic holders Ó To air cut off valve Ô To engine Õ Fasten the throttle position sensor lead carbure tor heater lead and fuel pump lead to the fuel pump bracket with the plastic locking tie Ö Fasten the fuel pump lead with the plastic holder B A B Ê È Ò È Ò Ñ Ñ Ó Ô Ð É Ë Ì Í Î Ï 4 1 D C 8 6 5 B A 0 2 3 5 6 7 8 9 Õ Ö A ...

Page 24: ...ight 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 Stator coil lead G Neutral switch lead H Speed sensor lead I Clutch cable A B 3 9 Õ D D C B A 0 C Ñ 1 2 3 4 5 6 I H G F E 7 8 9 Ô Ó Ó Ò É Ê Ë Ì Î Ï Ð È Í A B ...

Page 25: ...ith the plastic band Ì Fasten the wire harness and negative battery lead with the plastic holder Í 25 35 mm 0 98 1 38 in Î Fasten the tail brake light lead with the plastic holders Ï Pass the positive battery lead through the hole in the battery box Ð Fasten the sidestand switch lead horn lead starter motor lead and pickup coil lead with the plastic holder Ñ Fasten the pickup coil lead with the me...

Page 26: ...ad with the plastic holder Ó Fasten the starter motor lead sidestand switch lead and horn lead to the frame with the plastic locking ties Ô Fasten the clutch cable to the oil delivery pipe with the plastic holder Õ Attach the plastic holder to the curved section of the oil delivery pipe A B 3 9 Õ D D C B A 0 C Ñ 1 2 3 4 5 6 I H G F E 7 8 9 Ô Ó Ó Ò É Ê Ë Ì Î Ï Ð È Í A B ...

Page 27: ...s 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 motor lead G Sidestand switch lead H Decompression solenoid lead I Stator coil lead J Rollover valve A 1 2 3 4 5 6 7 8 9 0 A B 5 C D E F G 5 H I J È É Ê Ì Í Î Ï Ñ Ð Ë A ...

Page 28: ...and fuel tank breather hose with the plastic holder Ê Fasten the throttle cables with the plastic holder Ë To stator coil Ì To decompression solenoid Í To fuel tank Î To wire harness Ï To starter relay Ð To decompression solenoid Ñ To speed sensor A 1 2 3 4 5 6 7 8 9 0 A B 5 C D E F G 5 H I J È É Ê Ì Í Î Ï Ñ Ð Ë A ...

Page 29: ... 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 Solenoid valve lead for California D Spark plug lead 4 E Spark plug lead 2 F Spark plug lead 1 G Spark plug lead 3 5 4 3 1 2 8 7 6 Ë Ê Ì Ð Î È 0 A B C D E F G 9 Ï Í É Ñ ...

Page 30: ...he yellow tape on the wire harness with the hole in battery box as shown Í Insert the negative battery lead coupler into the slit in the battery band Î Route the starter motor lead between the battery box and plastic bracket Ï Install the sleeve of the negative battery lead between the negative battery lead coupler and plastic holder Ð To main switch Ñ To meter assembly 5 4 3 1 2 8 7 6 Ë Ê Ì Ð Î È...

Page 31: ...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 to charcoal canister hose C Solenoid valve to 3 way joint hose D Solenoid valve to air filter case hose E Solenoid valve A 5 4 3 2 3 2 1 1 8 9 9 0 CD E A B 7 6 Ï Ð Ë Î Ì Í Ê È É A ...

Page 32: ... Ë Fasten the compensator breather hose with the plastic holder Ì Fasten the clutch cable and rollover valve to 3 way joint hose with the plastic holders Í Fasten the starter motor lead and horn lead with the plastic holder Î To compensator Ï To air filter case Ð Fasten the solenoid valve lead to the ignition coil bracket with the plastic locking tie A 5 4 3 2 3 2 1 1 8 9 9 0 CD E A B 7 6 Ï Ð Ë Î ...

Page 33: ...ROUTING 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 7 2 1 3 A B A B ...

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 engine is cold 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Idle speed Check and adjust engine idle speed 7 Exhaust system Check for leakage Tighten if neces...

Page 35: ...lightly 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 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leakage Replace if necessary 18 Shock absorber assembly Check operation and for oil leakage Replac...

Page 36: ...e 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 and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if...

Page 37: ...S 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 installation reverse the removal pro cedure ...

Page 38: ...the 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 disconnecting the fuel hose set the fuel cock to OFF 5 Fuel sender coupler 1 Disconnect 6 Fuel tank 1 For installation reverse the removal pro cedure ...

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 axle 1 5 Front wheel 1 6 Collar left and right 2 7 Brake disc left and right 2 For installation reverse the removal pro cedure FRONT WHEEL AND BRAKE DISCS ...

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 28197 E0 1 Upper drive belt cover 1 2 Brake caliper 1 3 Brake caliper bracket bolt 1 4 Locknut left and right 2 Loosen 5 Adjusting bolt left and right 2 Loosen 6 Wheel axle nut 1 ...

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 installation reverse the removal pro cedure ...

Page 42: ...t 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 bolt 2 3 Brake pad clip 2 4 Brake pad pin 1 5 Brake pad spring 1 6 Brake pad 2 7 Brake pad shim 2 For installation reverse the removal pro cedure ...

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 pads 1 along with the brake pad shims brake pad shims 1 4 Measure brake pad wear limit a Out of specification Replace the brake pads as a set Brake pad wear limit 0 5 mm 0 02 in a ...

Page 44: ...bleed 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 Install brake caliper brake caliper bolts 7 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter ...

Page 45: ...the 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 fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Union bolt 1 8 Copper washer 2 9 Brake hose 1 Disconnect 10 Rear brake light switch 1 Disconnect ...

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: ...pers 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 CALIPERS and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper bolt 2 6 Brake caliper 1 For installation reverse the removal pro cedure ...

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 shim 2 6 Brake caliper piston 4 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS 7 Brake caliper piston seal 8 8 Bleed screw 1 For assembly reverse the disassembly procedure ...

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 compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper WARNING _ Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Remo...

Page 50: ...ever 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 caliper body Cracks damage Replace the brake cali per assembly brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING _ Whenever a brake caliper is disassem...

Page 51: ...ever 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 _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the brake hose onto the brake caliper 1 make sure the brake pipe ...

Page 52: ...formance 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 _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

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: ...isted 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 Throttle cable holder 1 8 Throttle cable 2 Disconnect 9 Grip end 2 10 Throttle grip 1 11 Clutch switch coupler 1 Disconnect ...

Page 55: ...marks 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 installation reverse the removal pro cedure ...

Page 56: ...rm 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 Disconnect 6 Horn 1 7 Self locking nut 1 8 Bolt shock absorber connecting arm frame 1 158 mm 6 22 in 9 Cover left and right 2 10 Pivot shaft nut washer 1 1 ...

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: ...s 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 ring 1 2 7 Self locking nut washer bolt 1 1 1 Bolt 77 mm 3 03 in 8 Relay arm 1 9 Spacer oil seal bearing 1 2 1 10 Spacer bearing 1 2 ...

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: ...e 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 pulley cover 1 3 Dowel pin 2 4 Slider 2 5 Drive belt 1 6 Drive pulley nut 1 7 Lock washer 1 8 Drive pulley 1 For installation reverse the removal pro cedure ...

Page 61: ...r 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 60 mm 2 36 in 4 Bolt 12 50 mm 1 97 in 5 Bolt 12 40 mm 1 57 in 6 Rear cylinder head cover 1 Refer to INSTALLING THE CYLINDER HEAD COVERS 7 Front cylinder head cover 1 8 Cylinder head cover gasket 2 9...

Page 62: ...ts 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 LIFT ERS in chapter 5 Manual No 4WM 28197 E0 and INSTALLING THE ROCKER ARMS AND PUSH RODS 4 Front rocker arm base 1 5 Rocker arm base gasket 2 6 Dowel pin 4 7 Rocker arm shaft 4 8 Rocker arm 1 2 9 Ro...

Page 63: ...ove 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 PUSH RODS AND VALVE LIFT ERS in chapter 5 Manual No 4WM 28197 E0 and INSTALLING THE VALVE LIFTERS AND PUSH ROD COV ERS in chapter 5 Manual No 4WM 28197 E0 For installation reverse the removal pro ce...

Page 64: ...ase 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 the motorcycle È Rear cylinder É Front cylinder 1 Intake side rocker arm 2 Exhaust side rocker arm 3 Intake valve lifter 4 Exhaust valve lifter 5 Push rod 1 288 5 mm 11 358 in green painting 6 Push rod ...

Page 65: ...M8 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 ders 1 Install dowel pins 1 cylinder head cover gasket 2 New 2 Install cylinder head cover 1 Bolts 2 40 mm 1 57 in Bolts 3 50 mm 1 97 in Bolts 4 60 mm 2 36 in Apply Quick Gasket to the thread T R 10 N...

Page 66: ...fer 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 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Pull rod 1 6 Friction plate 8 7 Clutch plate 7 8 Wire circlip 1 9 Clutch plate 1 ...

Page 67: ...per 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 drive gear 1 22 Straight key 1 For installation reverse the removal pro cedure ...

Page 68: ...utch 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 aligned with the groove in the main axle T R 105 Nm 10 5 m kg 75 ft lb ...

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 idle gear 2 1 4 Starter clutch idle gear 1 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 For installation reverse the removal pro cedure ...

Page 70: ...t 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 connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their orig inal positions a Clean the big end bear...

Page 71: ...olybdenum 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 are aligned e Tighten the connecting rod bolts WARNING Replace the connecting rod bolts with new ones Clean the connecting rod bolts NOTE The tightening procedure of the connecting rod bolts is angle...

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 bearings Refer to REMOVING THE CONNECTING RODS in chapter 5 Manual No 4WM 28197 E0 i Measure the compressed Plastigauge width e on each crankshaft pin If the crankshaft pin to big end bearing clearance is ...

Page 73: ...aft 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 BEARING COLOR CODE 1 blue 2 black 3 brown 4 green 5 yellow 5 Measure crankshaft journal diameter a Out of specification Replace the crank shaft NOTE Measure the diameter of each crankshaft jour nal a...

Page 74: ...te 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 crankshaft journal diameter from the crank shaft journal bearing inside diameter Crankshaft journal to crankshaft journal bearing clearance 0 030 0 062 mm 0 0012 0 0024 in INSTALLING THE CONNECTING RODS 1...

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 Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten connecting rod bolts 1 WARNING Replace the connecting rod bolts with new ones Clean the connecting ...

Page 76: ...specified 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 Tighten the bolt until it is at the specified angle NOTE The angle between the corners of the connect ing rod bolts is 30 T R Connecting rod bolts 1st 15 mm 1 5 m kg 11 ft lb T R Connecting rod bolts Fi...

Page 77: ...e 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 4th pinion gear 1 8 Spacer 1 9 Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure ...

Page 78: ...S00509 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 È To the carburetor joint É To the air cut off valve 5 4 3 1 2 6 È È 1 2 É A A AIR INDUCTION SYSTEM ...

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 to rear cylinder head hose 2 1 4 Reed valve case to rear cylinder head pipe 2 1 5 Gasket 2 6 Reed valve case to front cylinder head hose 1 ...

Page 80: ...e 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 Plastic locking tie 1 16 Vacuum hose 1 17 Bracket 1 18 Air cut off valve holder 1 19 Air cut off valve 1 ...

Page 81: ...M 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 reverse the removal pro cedure ...

Page 82: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 83: ...C 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 unit 0 Fuel pump A Sidestand switch B Ignitor unit C Ignition coil D Spark plug E Decompression solenoid F Throttle position sensor G Pickup coil H Speed sensor I Meter assembly J Neutral indicator li...

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