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Yamaha Road STAR WARRIOR XV17PC Full Service & Repair Manual 2002-2006

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🏷️ Basic Information Identification Make: Yamaha Model: Road Star Warrior Model Code: XV17PC Year Range: 2002-2006 Codes Vin Code: 5PX 👋 Introduction Market Position Category: Performance Cruiser Motorcycle Target Audience:...
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Yamaha Road STAR WARRIOR XV17PC Full Service & Repair Manual 2002-2006
🏷️ Basic Information
Identification
Make:
Yamaha
Model:
Road Star Warrior
Model Code:
XV17PC
Year Range:
2002-2006
Codes
Vin Code:
5PX
👋 Introduction
Market Position
Category:
Performance Cruiser Motorcycle
Target Audience:
Enthusiasts seeking a powerful, customizable cruiser with sportbike handling characteristics.
Competitive Analysis
Competitors:
Harley-Davidson V-Rod, Honda VTX1800, Kawasaki Vulcan 2000, Suzuki Boulevard M109R.
Key Features
Engine Type:
V-twin, liquid-cooled
Handling:
Unique blend of cruiser comfort and sportbike agility.
Design:
Muscular styling, low-slung profile, premium finish.
📋 Manual Details
Coverage Areas
Manual Type:
Factory Service Repair Workshop Manual
Language:
English
Format:
Digital Download (PDF)
Licensing:
No Expiry Dates, No Extra Fees
📖 Manual Coverage
Systems Covered
Engine:
Complete engine disassembly, assembly, inspection, and repair procedures.
Fuel System:
Fuel injection system (EFI) diagnostics, component testing, injector service, fuel pump, fuel pressure regulation.
Ignition System:
Ignition coil testing, spark plug specifications, ECU control, timing adjustments.
Transmission:
Clutch operation, gearbox inspection, lubrication, maintenance.
Drivetrain:
Shaft drive system inspection, maintenance, universal joint service.
Suspension:
Front fork disassembly, service, oil change, rear shock absorber inspection and replacement.
Brakes:
Front and rear brake system service, hydraulic fluid replacement, caliper and master cylinder overhaul, rotor inspection.
Electrical System:
Wiring diagrams, charging system (stator, regulator/rectifier), starter motor, lighting, battery maintenance, fuse and relay locations.
Cooling System:
Radiator, cooling fan, coolant type, bleeding procedures.
Exhaust System:
Exhaust pipe and muffler inspection and replacement.
Frame And Bodywork:
Frame inspection, fairing removal and installation, seat service, fuel tank removal.
Wheels And Tires:
Wheel bearing service, tire pressure specifications, wheel removal and installation.
Controls:
Handlebar, throttle control, clutch lever, brake lever service and adjustment.
Procedures Included
Routine Maintenance:
Oil changes, filter replacements, chain lubrication (if applicable, though this is shaft drive), spark plug checks, air filter cleaning/replacement.
Troubleshooting:
Diagnostic flowcharts for common problems, symptom-based troubleshooting guides.
Repair Procedures:
Step-by-step instructions for component removal, overhaul, and reinstallation.
Component Overhaul:
Detailed procedures for rebuilding major components like the engine, transmission, and brake calipers.
Electrical Diagnostics:
Testing electrical circuits, component resistance checks, voltage measurements.
Torque Specifications:
Essential torque values for all critical fasteners and assemblies.
Special Tools:
Identification of any specialized tools required for specific procedures.
Technical Depth
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced diagnostics.
📊 Manual Specifications
File Format
Format:
PDF
Searchability:
Searchable text content
Printability:
Printable pages
Quality:
High-resolution, clear diagrams and text
Binding Type
Binding:
N/A (Digital Download)
Paper Type
Paper:
N/A (Digital Download)
⚙️ Engine Specifications
Primary Engine
Engine Type:
Air-cooled, 4-stroke, SOHC, 4-valve per cylinder V-twin
Displacement:
1670 cc (102 cu in)
Bore X Stroke:
97.0 mm x 113.0 mm (3.82 in x 4.45 in)
Compression Ratio:
8.4:1
Performance
Horsepower:
Approx. 100 hp @ 5500 rpm (claimed)
Torque:
Approx. 116 ft-lbs @ 3750 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (EFI) with Mikuni throttle body
Fuel Type:
Unleaded gasoline, 90 octane or higher recommended
Lubrication
Oil Type:
Yamalube 4 (or equivalent) SAE 20W-40 API SG or higher
Oil Capacity:
3.40 L (3.59 US qt) / 3.10 L (3.28 US qt) without filter change
🔧 Transmission
Standard
Transmission Type:
Constant mesh 5-speed
Final Drive:
Shaft drive
Features
Clutch Type:
Wet, multi-disc
📐 Dimensions
Exterior
Overall Length:
2340 mm (92.1 in)
Overall Width:
870 mm (34.3 in)
Overall Height:
1150 mm (45.3 in)
Seat Height:
710 mm (28.0 in)
Wheelbase:
1670 mm (65.7 in)
Weights
Dry Weight:
257 kg (567 lbs)
Wet Weight:
Approx. 273 kg (602 lbs) (fully fueled)
Fuel Capacity:
20.0 L (5.3 US gal)
🛡️ Safety Features
Ratings
Safety Certifications:
Meets or exceeds relevant motorcycle safety standards for its production era.
Active Features
Brakes:
Hydraulic dual disc front brakes, hydraulic single disc rear brake. ABS was not typically standard or an option for this model.
Lighting:
Halogen headlight, LED tail light, incandescent turn signals.
Passive Features
Frame Construction:
Steel double-cradle frame for stability.
💡 Technology Features
Infotainment
Infotainment System:
Not applicable for this model year; basic analog instrumentation.
Driver Assistance
Assistance Features:
ABS was not a standard or common option. Primarily focused on mechanical performance and rider feedback.
Connectivity
Connectivity Features:
None. The focus is on raw mechanical performance and rider experience.
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 4,000 miles (6,000 km) or 6 months, whichever comes first.
Oil Filter Change:
With every oil change.
Spark Plug Inspection:
Every 8,000 miles (12,000 km).
Air Filter Cleaning:
Every 4,000 miles (6,000 km), or more often in dusty conditions.
Brake Fluid Flush:
Every 2 years or as needed.
Final Drive Oil Change:
Every 10,000 miles (16,000 km).
Fluid Specifications
Engine Oil Grade:
Yamalube 4 (or equivalent) SAE 20W-40 API SG or higher
Brake Fluid Type:
DOT 4
Coolant Type:
Ethylene glycol-based coolant, 50% mixture with distilled water
Final Drive Oil Type:
Yamalube Gear Oil (or equivalent) SAE 80 API GL-4
Known Issues
Starter Clutch:
Some owners report occasional starter clutch noise or failure, often related to age and usage.
Rear Drive Pinion Seal:
Potential for leaks at the rear drive pinion seal over time.
Efi Sensors:
While generally reliable, EFI sensors (e.g., TPS, MAP) can degrade with age, potentially causing performance issues.
📚 Vehicle History
Brand Heritage
Manufacturer:
Yamaha Motor Corporation, founded in 1955, renowned for motorcycles, musical instruments, and other powered products.
Model Evolution
Introduction Year:
2002
Design Philosophy:
To create a muscle cruiser with enhanced sporting capability and a distinctive, powerful aesthetic, distinguishing it from Yamaha's more traditional cruisers.
Updates Within Range:
Minor color and graphic updates, potential ECU tuning adjustments across the 2002-2006 period. No major mechanical redesigns within this timeframe.
Production
Production Location:
Japan
🏆 Awards & Recognition
Recognitions
Industry Reputation:
Widely praised in its time for its powerful engine, unique styling, and surprisingly agile handling for a large-displacement cruiser, carving out a distinct niche in the market.
Ratings
Performance Reviews:
Consistently received positive reviews from motorcycle publications for its V-twin power delivery and handling characteristics.
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