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EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. ECA13300 NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfaces. EAS20240 CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip “1”, make sure the sharp-edged corner “2” is positioned opposite the thrust “3” that the circlip receives. 1-35 IMPORTANT INFORMATION
EAS20250 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: Lead Coupler Connector 2. Check: Lead Coupler Connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3. Check: All connections Loose connection → Connect properly. TIP If the pin “1” on the terminal is flattened, bend it up. 4. Connect: Lead Coupler Connector TIP Make sure all connections are tight. 5. Check: Continuity (with the pocket tester) CHECKING THE CONNECTIONS 1-36 Pocket tester 90890-03112 Analog pocket tester YU-03112-C TIP If there is no continuity, clean the terminals. When checking the wire harness, perform steps (1) to (3). As a quick remedy, use a contact revitalizer available at most part stores.
Page 1 and 2: SERVICE MANUAL VMX17Y(C) 2009 LIT-1
Page 3 and 4: EAS20071 IMPORTANT This manual was
Page 5: EAS20100 SYMBOLS The following symb
Page 9 and 10: GENERAL INFORMATION IDENTIFICATION
Page 11 and 12: EAS20170 FEATURES 1-2 FEATURES EAS3
Page 13 and 14: 1-4 FEATURES EAS2S31084 OUTLINE OF
Page 15 and 16: a. Friction force between the tire
Page 17 and 18: a. Friction force between the tire
Page 19 and 20: 1-10 FEATURES The front and rear se
Page 21 and 22: 1 2 1-12 FEATURES Buffer chamber Th
Page 23 and 24: 1-14 FEATURES TIP Some types of mal
Page 25 and 26: 1-16 FEATURES Emergency braking (AB
Page 27 and 28: 1-18 FEATURES Instances when the AB
Page 29 and 30: EAS2S31088 ABS WARNING LIGHT AND OP
Page 31 and 32: 1-22 FEATURES EAS2S31089 YCC-T (YAM
Page 33 and 34: YCC-T/YCC-I system outline 1 13 14
Page 35 and 36: EAS2S31097 INSTRUMENT FUNCTIONS 1.
Page 37 and 38: 2. Push “RESET”. 3. Push “SEL
Page 39 and 40: 1. Push “SELECT” to highlight
Page 41 and 42: If, when the engine is running whil
Page 43: EAS20180 IMPORTANT INFORMATION EAS2
Page 47 and 48: Oil filter wrench 90890-01426 YU-38
Page 49 and 50: Valve guide installer (ø5) 90890-0
Page 51 and 52: Radiator cap tester adapter 90890-0
Page 53 and 54: SPECIFICATIONS GENERAL SPECIFICATIO
Page 55 and 56: EAS20290 ENGINE SPECIFICATIONS 2-2
Page 57 and 58: 2-4 ENGINE SPECIFICATIONS Exhaust B
Page 59 and 60: 2-6 ENGINE SPECIFICATIONS Cylinder
Page 61 and 62: Primary reduction ratio 86/57 (1.50
Page 63 and 64: EAS20300 CHASSIS SPECIFICATIONS Cha
Page 65 and 66: Standard 4 Maximum 1 Rebound dampin
Page 67 and 68: Engine trouble warning light LED AB
Page 69 and 70: EAS20320 TIGHTENING TORQUES EAS2033
Page 71 and 72: Item Thread size 2-18 TIGHTENING TO
Page 75 and 76: Crankcase tightening sequence A 15
Page 83 and 84: Shift forks and shift fork guide ba
Page 85 and 86: LUBRICATION POINTS AND LUBRICANT TY
Page 87 and 88: 1. Oil pan 2. Oil strainer 3. Oil p
Page 89 and 90: 1. Timing chain tensioner (rear cyl
Page 91 and 92: 1. Balancer shaft 2. Main axle 3. D
Page 93 and 94: 1. Crankshaft 2. Main gallery bolt
Page 95 and 96:
1. Oil filter cartridge 2. Oil nozz
Page 97 and 98:
1. Thermostat inlet pipe (rear cyli
Page 99 and 100:
1. Thermostat outlet hose 2. Upper
Page 101 and 102:
1. Front brake light switch lead 2.
Page 103 and 104:
1. Throttle cables 2. Brake hose (f
Page 105 and 106:
1. Meter assembly 2 coupler 2. Igni
Page 107 and 108:
1. Radiator fan motor relay 2. Head
Page 109 and 110:
1. Meter assembly 2 2. Main switch
Page 111 and 112:
1. ABS test coupler 2. Fuel tank br
Page 113 and 114:
1. Meter assembly 1 lead 2. Upper r
Page 115 and 116:
1. Fuel pump coupler 2. Rear left t
Page 117 and 118:
1. ECU (engine control unit) 2. Wir
Page 119 and 120:
1. Accelerator position sensor 2. T
Page 121 and 122:
1. Brake hose (hydraulic unit to le
Page 123 and 124:
1. Clutch hose 2. Brake hose (hydra
Page 125 and 126:
PERIODIC CHECKS AND ADJUSTMENTS PER
Page 128 and 129:
EAS20450 PERIODIC MAINTENANCE 3-1 P
Page 130 and 131:
No. ITEM ROUTINE 25 Final gear oil
Page 132 and 133:
. Turn the crankshaft almost 1/2 of
Page 134 and 135:
2 1 g. Install the exhaust and inta
Page 136 and 137:
EAS20630 ADJUSTING THE THROTTLE CAB
Page 138 and 139:
EAS20780 CHANGING THE ENGINE OIL 1.
Page 140 and 141:
a ▲▲▲▲▲▲▲▲▲▲▲
Page 142 and 143:
ECA2S31058 NOTICE Never operate the
Page 144 and 145:
17 18 8 4 15 16 5 20 9 3 9 14 14 8
Page 146 and 147:
• Upper radiator inlet pipe “3
Page 148 and 149:
13.Install: • Coolant reservoir c
Page 150 and 151:
TIP In order to ensure a correct re
Page 152 and 153:
ECA2S31005 NOTICE Make sure that th
Page 154 and 155:
. Loosen the lower ring nut “4”
Page 156 and 157:
Rebound damping ECA13590 NOTICE Nev
Page 158 and 159:
Compression damping adjusting posit
Page 160 and 161:
3. Check: • Wheel bearings Refer
Page 162 and 163:
▼▼▼▼▼▼▼▼▼▼▼
Page 164 and 165:
REAR BRAKE ........................
Page 166 and 167:
EAS21830 GENERAL CHASSIS Removing t
Page 168 and 169:
4-3 GENERAL CHASSIS Removing the si
Page 170 and 171:
Removing the passenger footrests an
Page 172 and 173:
Disassembling the intake duct assem
Page 174 and 175:
Removing the battery T.R. 10 Nm (1.
Page 176 and 177:
Removing the meter assembly 1 and h
Page 178 and 179:
Disassembling the front wheel New 1
Page 180 and 181:
• Front wheel Damage/wear → Rep
Page 182 and 183:
ECA2S31010 NOTICE Replace the wheel
Page 184 and 185:
d. In the order pinch bolt “3”
Page 186 and 187:
Removing the rear wheel, brake disc
Page 188 and 189:
EAS22050 REMOVING THE REAR WHEEL (D
Page 190 and 191:
1. Install: • Bearing “1” 2.
Page 192 and 193:
5. Tighten: • Rear wheel axle •
Page 194 and 195:
EAS22210 FRONT BRAKE Removing the f
Page 196 and 197:
Disassembling the front brake maste
Page 198 and 199:
Disassembling the front brake calip
Page 200 and 201:
d. Measure the brake disc deflectio
Page 202 and 203:
EAS22390 CHECKING THE FRONT BRAKE C
Page 204 and 205:
TIP To collect any remaining brake
Page 206 and 207:
EAS22550 REAR BRAKE Removing the re
Page 208 and 209:
Removing the rear brake master cyli
Page 210 and 211:
Removing the rear brake caliper T.R
Page 212 and 213:
EAS22560 INTRODUCTION EWA14100 WARN
Page 214 and 215:
EAS22600 DISASSEMBLING THE REAR BRA
Page 216 and 217:
▲▲▲▲▲▲▲▲▲▲▲
Page 218 and 219:
2. Install: • Brake hose gaskets
Page 220 and 221:
EAS22760 ABS (ANTI-LOCK BRAKE SYSTE
Page 222 and 223:
EAS2S31023 REMOVING THE HYDRAULIC U
Page 224 and 225:
6. Fill: • Brake master cylinder
Page 226 and 227:
5. Connect the test coupler adapter
Page 228 and 229:
EAS22840 HANDLEBAR Removing the han
Page 230 and 231:
EAS22860 REMOVING THE HANDLEBAR 1.
Page 232 and 233:
TIP • Align the mating surfaces o
Page 234 and 235:
Removing the front fork legs LT T.R
Page 236 and 237:
Disassembling the front fork legs T
Page 238 and 239:
TIP While holding the damper rod wi
Page 240 and 241:
6. Install: • Oil seal “1” (w
Page 242 and 243:
a. More than 12 mm (0.47 in) ▲▲
Page 244 and 245:
Removing the coupler holder and bra
Page 246 and 247:
EAS23110 REMOVING THE LOWER BRACKET
Page 248 and 249:
EAS23160 REAR SHOCK ABSORBER ASSEMB
Page 250 and 251:
EAS23170 HANDLING THE REAR SHOCK AB
Page 252 and 253:
TIP • Hold the connecting arm and
Page 254 and 255:
EAS23350 REMOVING THE SWINGARM 1. S
Page 256 and 257:
EAS23551 SHAFT DRIVE Removing the f
Page 258 and 259:
Disassembling the final drive assem
Page 260 and 261:
EAS23560 TROUBLESHOOTING 4-95 SHAFT
Page 262 and 263:
4. Measure: • Final gear backlash
Page 264 and 265:
4. Remove: • Bearing retainer (wi
Page 266 and 267:
Final drive pinion gear shims Thick
Page 268 and 269:
e. Measure the width of the flatten
Page 270 and 271:
4-105 SHAFT DRIVE
Page 272 and 273:
CLUTCH ............................
Page 274 and 275:
EAS23711 ENGINE REMOVAL Removing th
Page 276 and 277:
Disconnecting the leads and hose 1
Page 278 and 279:
Removing the engine T.R. T.R. T.R.
Page 280 and 281:
EAS23720 INSTALLING THE ENGINE 1. I
Page 282 and 283:
EAS23760 CAMSHAFTS Removing the cyl
Page 284 and 285:
Removing the camshafts (16) M T.R.
Page 286 and 287:
EAS23820 REMOVING THE CAMSHAFTS Rea
Page 288 and 289:
3. Measure: • Camshaft runout Out
Page 290 and 291:
2 b. Install the timing chain tensi
Page 292 and 293:
5. Install: • Intake camshaft cap
Page 294 and 295:
T R . . TIP • Install the camshaf
Page 296 and 297:
9. Check that the timing chain is t
Page 298 and 299:
9. Install: • Ignition coils “1
Page 300 and 301:
EAS24140 REMOVING THE CYLINDER HEAD
Page 302 and 303:
EAS24270 VALVES AND VALVE SPRINGS R
Page 304 and 305:
1. Measure: • Valve-stem-to-valve
Page 306 and 307:
. Install the valve into the cylind
Page 308 and 309:
2. Lubricate: • Valve stem “1
Page 310 and 311:
EAS24480 GENERATOR AND STARTER CLUT
Page 312 and 313:
Removing the generator rotor and st
Page 314 and 315:
4. Check: • Starter clutch operat
Page 316 and 317:
GENERATOR AND STARTER CLUTCH a 1 5-
Page 318 and 319:
Disassembling the starter motor 13
Page 320 and 321:
7. Check: • Pinion gear teeth Dam
Page 322 and 323:
Removing the clutch E T.R. 18 New E
Page 324 and 325:
Removing the clutch master cylinder
Page 326 and 327:
Disassembling the clutch master cyl
Page 328 and 329:
Disassembling the clutch release cy
Page 330 and 331:
EAS25110 CHECKING THE CLUTCH PLATES
Page 332 and 333:
EAS25260 INSTALLING THE CLUTCH 1. I
Page 334 and 335:
EAS25290 CHECKING THE CLUTCH MASTER
Page 336 and 337:
1. Check: • Clutch release cylind
Page 338 and 339:
EAS25410 SHIFT SHAFT Removing the s
Page 340 and 341:
EAS25420 CHECKING THE SHIFT SHAFT 1
Page 342 and 343:
Removing the oil pan and oil pump a
Page 344 and 345:
EAS24930 REMOVING THE OIL PAN 1. Re
Page 346 and 347:
EAS25540 CRANKCASE Separating the c
Page 348 and 349:
Removing the plate, oil pipe 3, and
Page 350 and 351:
EAS2S31040 CHECKING THE TIMING CHAI
Page 352 and 353:
EWA2S31013 WARNING If the bolt is t
Page 354 and 355:
EAS2S31041 CONNECTING RODS AND PIST
Page 356 and 357:
1. Check: • Piston wall • Cylin
Page 358 and 359:
Piston pin bore inside diameter 19.
Page 360 and 361:
EWA2S31038 WARNING • When a bolt
Page 362 and 363:
TIP Be sure to install the piston r
Page 364 and 365:
a ▲▲▲▲▲▲▲▲▲▲▲
Page 366 and 367:
EAS2S31094 REMOVING THE BALANCER SH
Page 368 and 369:
B J1 J2 J3 J4 For example, if the l
Page 370 and 371:
TIP • Align the projections “a
Page 372 and 373:
Disassembling the main axle assembl
Page 374 and 375:
Disassembling the drive axle/middle
Page 376 and 377:
3. Check: • Transmission gears Bl
Page 378 and 379:
EAS25711 MIDDLE GEAR Removing the m
Page 380 and 381:
Removing the middle drive pinion ge
Page 382 and 383:
EAS2S31047 REMOVING THE MIDDLE DRIV
Page 384 and 385:
TIP While compressing the spring wi
Page 386 and 387:
2 ▲▲▲▲▲▲▲▲▲▲▲
Page 388 and 389:
TIP Select the middle driven pinion
Page 390 and 391:
5-117 MIDDLE GEAR
Page 392 and 393:
EAS2S31078 RADIATORS Removing the r
Page 394 and 395:
Disassembling the radiators T.R. T.
Page 396 and 397:
EAS26410 OIL COOLER Removing the oi
Page 398 and 399:
EAS26440 THERMOSTAT Removing the th
Page 400 and 401:
EAS26450 CHECKING THE THERMOSTAT 1.
Page 402 and 403:
EAS26500 WATER PUMP Removing the wa
Page 404 and 405:
EAS26510 DISASSEMBLING THE WATER PU
Page 406 and 407:
6-15 WATER PUMP
Page 408 and 409:
EAS26620 FUEL TANK Removing the fue
Page 410 and 411:
EAS26630 REMOVING THE FUEL TANK 1.
Page 412 and 413:
c. Connect the pressure gauge “2
Page 414 and 415:
Removing the air filter case and in
Page 416 and 417:
1 EAS2S31007 INSTALLING THE AIR FIL
Page 418 and 419:
EAS26970 THROTTLE BODIES Removing t
Page 420 and 421:
Removing the injectors T.R. 3.5 Nm
Page 422 and 423:
Pressure drops → Properly install
Page 424 and 425:
2. Adjust: • Throttle position se
Page 426 and 427:
EAS27040 AIR INDUCTION SYSTEM B 6 6
Page 428 and 429:
Removing the air cut-off valve asse
Page 430 and 431:
EAS27060 CHECKING THE AIR INDUCTION
Page 432:
ABS (ANTI-LOCK BRAKE SYSTEM).......
Page 435 and 436:
6. Main fuse 7. Main switch 8. Batt
Page 437 and 438:
EAS27140 TROUBLESHOOTING The igniti
Page 439 and 440:
8-6 IGNITION SYSTEM
Page 441 and 442:
Page 443 and 444:
EAS27190 TROUBLESHOOTING The starte
Page 445 and 446:
8-12 ELECTRIC STARTING SYSTEM
Page 447 and 448:
1. AC magneto 2. Rectifier/regulato
Page 449 and 450:
8-16 CHARGING SYSTEM
Page 451 and 452:
Page 453 and 454:
7. Check the entire lighting system
Page 455 and 456:
Page 457 and 458:
2. Check the horn. Refer to “CHEC
Page 459 and 460:
2. Check the entire signaling syste
Page 461 and 462:
8-28 SIGNALING SYSTEM
Page 463 and 464:
Page 465 and 466:
8-32 COOLING SYSTEM
Page 467 and 468:
3. Fuel injection system fuse 5. El
Page 469 and 470:
a. Main switch “OFF” b. Main sw
Page 471 and 472:
8-38 FUEL INJECTION SYSTEM • To i
Page 473 and 474:
Diagnostic code No. D:60 EEPROM fau
Page 475 and 476:
Diagnostic code No. D:39 Injector #
Page 477 and 478:
8-44 FUEL INJECTION SYSTEM Fault co
Page 479 and 480:
Fault code No. 15 D:13 Meter displa
Page 481 and 482:
Fault code No. 19 Item Fail-safe sy
Page 483 and 484:
Fault code No. 22 8-50 FUEL INJECTI
Page 485 and 486:
Fault code No. 30 Item Fail-safe sy
Page 487 and 488:
Fault code No. 34 Item 2 Open or sh
Page 489 and 490:
Fault code No. 36 Item 2 Open or sh
Page 491 and 492:
Page 493 and 494:
Fault code No. 42 Item B Fail-safe
Page 495 and 496:
Page 497 and 498:
Page 499 and 500:
Fault code No. ER-2 8-66 FUEL INJEC
Page 501 and 502:
8-68 FUEL INJECTION SYSTEM
Page 503 and 504:
3. Fuel injection system fuse 6. Ma
Page 505 and 506:
8-72 FUEL PUMP SYSTEM
Page 507 and 508:
4. ABS solenoid fuse 6. Main fuse 7
Page 509 and 510:
ABS (ANTI-LOCK BRAKE SYSTEM) 8-76
Page 511 and 512:
1. Meter assembly 1 coupler 2. ABS
Page 513 and 514:
ABS (ANTI-LOCK BRAKE SYSTEM) TIP Th
Page 515 and 516:
EWA2S31022 WARNING ABS (ANTI-LOCK B
Page 517 and 518:
ABS (ANTI-LOCK BRAKE SYSTEM) • If
Page 519 and 520:
Fault code No. ABS-22 ABS-24 ABS-31
Page 521 and 522:
Fault code No. ABS-11 ABS-25 Order
Page 523 and 524:
Page 525 and 526:
ABS (ANTI-LOCK BRAKE SYSTEM) Fault
Page 527 and 528:
Page 529 and 530:
Page 531 and 532:
Page 533 and 534:
Page 535 and 536:
Page 537 and 538:
Page 539 and 540:
Page 541 and 542:
Page 543 and 544:
Page 545 and 546:
Page 547 and 548:
EAS2S31075 [D-1] DELETING THE FAULT
Page 549 and 550:
ABS (ANTI-LOCK BRAKE SYSTEM) 8-116
Page 551 and 552:
1. Main switch 2. Clutch switch 3.
Page 553 and 554:
1. Air induction system solenoid 2.
Page 555 and 556:
1. Dimmer switch 2. Hazard switch 3
Page 557 and 558:
EAS27990 CHECKING THE BULBS AND BUL
Page 559 and 560:
EAS28030 CHECKING AND CHARGING THE
Page 561 and 562:
TIP Set the charging voltage to 16-
Page 563 and 564:
Radiator fan motor relay 3 4 2 G/Y
Page 565 and 566:
c. Measure the primary coil resista
Page 567 and 568:
EAS28150 CHECKING THE STATOR COIL 1
Page 569 and 570:
EAS29040 CHECKING THE FUEL LEVEL WA
Page 571 and 572:
EAS29100 CHECKING THE ACCELERATOR P
Page 573 and 574:
1. Check: • Intake air pressure s
Page 575 and 576:
TROUBLESHOOTING TROUBLESHOOTING....
Page 577 and 578:
Electrical system 1. Battery • Di
Page 579 and 580:
4. Swingarm • Worn bearing or bus
Page 582 and 583:
YAMAHA MOTOR CO., LTD. 2500 SHINGAI
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