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Yamaha Road STAR WARRIOR XV17PC Service Repair Manual 2002-2006

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🏷️ Basic Information Identification Make: Yamaha Model: Road Star Warrior Model Code: XV17PC Generation Production Years Covered: 2002-2006 👋 Introduction Market Position Motorcycle Segment: Cruiser/Performance Cruiser Competitive Analysis Competitors: Rivals...
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Yamaha Road STAR WARRIOR XV17PC Service Repair Manual 2002-2006
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Road Star Warrior
Model Code:
XV17PC
Generation
Production Years Covered:
2002-2006
👋 Introduction
Market Position
Motorcycle Segment:
Cruiser/Performance Cruiser
Competitive Analysis
Competitors:
Rivals included Harley-Davidson V-Rod, Indian Chief, and other large-displacement V-twin cruisers of the era.
Key Features
Performance Focus:
The Warrior was distinguished by its sportier handling and more powerful engine compared to the standard Road Star models, bridging the gap between traditional cruisers and sportbikes.
📋 Manual Details
Coverage Areas
Coverage Scope:
Comprehensive service and repair for Yamaha Road Star Warrior XV17PC motorcycles
Page Count
Estimated Page Count:
600+
Manual Type
Manual Type:
Service Repair Workshop Manual
Language
Language:
English
Format
Format:
PDF (Digital Download)
📖 Manual Coverage
Systems Covered
Engine System:
Detailed coverage of the 1700cc V-twin engine, including disassembly, assembly, component testing, and specifications.
Fuel System:
Comprehensive information on fuel injection system, throttle body, fuel pump, injectors, and related sensors.
Ignition System:
Details on ignition timing, coils, spark plugs, and electronic control unit (ECU) related diagnostics.
Transmission System:
Coverage of the 5-speed transmission, clutch operation, gears, bearings, and shift mechanism.
Chassis And Frame:
Information on frame inspection, suspension components (forks, rear shock), steering head bearings, and wheel alignment.
Brakes System:
Detailed procedures for front and rear brake systems, including disc replacement, caliper service, fluid bleeding, and hydraulic components.
Electrical System:
Wiring diagrams, troubleshooting for lighting, charging system (stator, regulator/rectifier), starter motor, battery, and switches.
Cooling System:
Details on the oil cooling system, including oil cooler, lines, and oil filtration.
Exhaust System:
Information on exhaust pipes, mufflers, and heat shields.
Bodywork And Trim:
Procedures for removing and installing body panels, fenders, fuel tank, seat, and other cosmetic components.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, spark plug maintenance, chain adjustment (if applicable), brake fluid flush, and general inspection.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, error code interpretation (if applicable).
Major Repairs:
Engine rebuilds, transmission overhauls, suspension upgrades, brake system overhauls, and electrical system repairs.
Component Disassembly And Reassembly:
Step-by-step guides for dismantling and reassembling all major motorcycle components.
Torque Specifications:
Essential torque values for critical fasteners to ensure proper assembly and prevent damage.
Technical Depth
Depth Of Information:
Factory-level detail suitable for professional mechanics and advanced DIY enthusiasts.
📊 Manual Specifications
File Format
File Type:
PDF
Print Quality
Resolution And Clarity:
High-resolution scans ensuring clear text and diagrams, suitable for printing.
Binding Type
Binding Format:
Digital PDF (no physical binding)
Paper Type
Paper Equivalent:
N/A (Digital format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, V-twin, SOHC, 4-valve per cylinder
Displacement:
1670 cc (102.0 cubic inches)
Bore X Stroke:
97.0 mm x 113.0 mm
Compression Ratio:
8.4:1
Performance
Horsepower Estimate:
Approx. 80-85 HP (at crankshaft)
Torque Estimate:
Approx. 100-105 lb-ft (at crankshaft)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with dual 37mm throttle bodies
Fuel Type:
Unleaded gasoline, minimum 87 octane
Lubrication System
Oil Type:
Yamalube 4 (or equivalent) SAE 20W-40 motorcycle oil
Oil Capacity:
4.4 Liters (4.6 US qt) with oil filter change
🔧 Transmission
Standard
Transmission Type:
Constant mesh 5-speed
Clutch Type:
Wet, multiple-disc
Final Drive:
Belt drive
Features
Gear Ratios:
Specific gear ratios would be detailed within the manual.
Fluid Specifications
Transmission Oil Type:
Yamaha recommends specific gear oil (refer to manual for exact spec/part number).
📐 Dimensions
Exterior
Length:
Approx. 2530 mm (99.6 in)
Width:
Approx. 990 mm (39.0 in)
Height:
Approx. 1300 mm (51.2 in)
Weights
Dry Weight:
Approx. 285 kg (628 lbs)
Wet Weight:
Approx. 303 kg (668 lbs)
Fuel Capacity:
20 Liters (5.3 US gal)
Wheels And Tires
Front Tire Size:
120/70 ZR18M/C (59W)
Rear Tire Size:
190/50 ZR17M/C (73W)
Wheel Bolt Pattern:
N/A (Cast wheels, hub-mounted)
🛡️ Safety Features
Ratings
Safety Features Standard:
Robust braking system, balanced chassis for stability.
Active Features
Braking System:
Dual 298mm front discs with 4-piston calipers, Single 282mm rear disc with 2-piston caliper.
Passive Features
Lighting:
Halogen headlight, LED taillight, turn signals.
💡 Technology Features
Infotainment
Instrumentation:
Analog speedometer, tachometer, fuel gauge, and indicator lights. Often includes digital trip meter.
Driver Assistance
ABS:
ABS was an optional feature on some models, not standard across all years/trims.
Connectivity
Engine Management:
ECU controlled fuel injection and ignition timing.
🔧 Maintenance
Service Intervals
Engine Oil And Filter:
Every 6,000 km (3,700 miles) or 6 months.
Air Filter Cleaning Or Replacement:
Every 12,000 km (7,500 miles).
Spark Plug Replacement:
Every 12,000 km (7,500 miles).
Brake Fluid Replacement:
Every 24,000 km (15,000 miles) or 2 years.
Fluid Specifications
Engine Oil Viscosity:
SAE 20W-40 is commonly recommended, but check specific conditions in manual.
Brake Fluid Type:
DOT 4
Known Issues
Common Wear Items:
Clutch plates, brake pads, fork seals, and drive belt can be common wear items depending on usage.
Potential Electrical Issues:
Wiring harness connectors, regulator/rectifier reliability (though generally robust).
📚 Vehicle History
Brand Heritage
Yamaha Motorcycles:
Yamaha Motor Company is renowned for its long history in motorcycle manufacturing, known for innovation, performance, and reliability across various segments.
Model Evolution
Road Star Lineage:
The Road Star line, introduced in the late 1990s, was Yamaha's answer to the classic American cruiser market. The Warrior variant, launched in 2002, injected a dose of performance and sport-oriented styling.
Production
Manufacturing Location:
Japan
🏆 Awards & Recognition
Recognitions
Market Reception:
Critically acclaimed for its blend of cruiser styling and performance capabilities, often praised for its powerful engine and capable chassis.
Ratings
Owner Satisfaction:
Generally high owner satisfaction due to performance and reliability, though specific issue areas can be addressed via the manual.
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