Yamaha Road Star 1600, 1700 Repair Manual 1999-2007

The 1999-2007 Yamaha Road Star repair manual by Clymer covers the following motorcycle models:

• Yamaha XV1600A, XV1700A RoadStar 1999-2007
• Yamaha XV1600AT, XV1700AT Road Star Silverado 1999-2007
• Yamaha XV1600AS Road Star MM Limited 2000
• Yamaha XV1600AS Road Star Midnight Star 2001-2003
• Yamaha XV1600ALE Road Star Limited Edition 2003
• Yamaha XV1600ATLE Road Star Silverado Limited Edition 2003
• Yamaha XV1700AM Road Star Midnight 2004-2007
• Yamaha XV1700ATM Road Star Midnight Silverado 2004-2007

Learn everything there is to know about the motorcycle you own, including valuable cost-saving tips on handling maintenance and repairs yourself, with the Yamaha Road Star 1600, 1700 Repair Manual 1999-2007 available at The Motor Bookstore. The Yamaha Road Star manual is the ticket to DIY maintenance on piston pin inspection, suspension and steering, the wheels and tires, the clutch and primary drive gear, the transfer gearcase, the fuel, exhaust and emission control systems and the 4-stroke V-twin engine. Hundreds of photos and illustrations are featured in the 452-page Clymer manual that is yours with free shipping when you order from The Motor Bookstore, which will ship your book within one business day of your order.

Note: this manual DOES NOT cover Yamaha XV1700P Warrior models.

Book Excerpt: 1999-2007 Yamaha RoadStar 1600, 1700 Repair Manual SUSPENSION AND STEERING

Poor handling may be caused by improper tire pressure, a damaged/bent frame steering componenets, a worn front fork assembly, worn wheel bearings or dragging brakes.
STEERING IS SLUGGISH

1. Incorrect steering stem adjustment (too tight).
2. Improperly installed upper or lower fork bridge.
3. Damaged steering head bearings.
4. Tire pressure too low.
5. Worn or damaged tire.

STEERING TO ONE SIDE

1. Bent front or rear axle.
2. Bent frame or fork.
3. Worn or damaged wheel bearings.
4. Worn or damaged swing arm pivot bearings.
5. Damaged steering head bearings.
6. Bent swing arm.
7. Incorrectly installed wheels.
8. Front and rear wheels are not aligned.
9. Uneven front fork adjustment.
10. Fork legs positioned unevenly in the fork bridges.

ENGINE TOP END

PISTON PIN INSPECTION When measuring the piston pin, compare the actual measurements to the specifications in Table 2. Replace the piston pin if out of specification or if it shows signs of damage as described in this section. If the piston pin is replaced, also replace the piston as a set.

1. Clean the piston pin in solvent and dry it thoroughly.
2. Inspect the piston pin for chrome flaking or cracks. Replace the pin if necessary.
3. Oil the piston pin and install it in the connecting rod. Slowly rotate the piston pin, and check for radial and lateral play (Figure 158). If there is play, the connecting rod should be replaced (if the piston pin outside diameter is within specification). Inspect the connecting rod as described in Chapter Five.
4. Measure the outside diameter of the piston pin with a micrometer (Figure 159).
5. Measure the inside diameter of the piston pin bore in the piston with a small bore gauge.
6. Subtract the measurements made in Step 5 from the measurements made in Step 6. The difference is the piston-to-pin clearance.

PISTON RING REMOVAL AND INSPECTION A three-ring assembly is used with each piston. The top and second rings are compression rings. The lower ring is an oil control ring assembly (consisting of two ring rails and an expander spacer). When measuring the piston rings in this section, compare the actual measurements to the specifications in Table 2. Replace the piston rings as a set if out of specification or if they show signs of damage as described in this section.

Subject: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007 Yamaha Road Star service, maintenance, and repair procedures. ISBN-10: 1599694158 | ISBN-13: 9781599694153 | Clymer M282-2