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Piston pin puller set 90890-01304 Piston pin puller YU-01304 Tool name/Tool No. Illustration Damper spring compressor 90890-04090 Middle drive shaft nut wrench (55 mm) 90890-04054 Offset wrench 55 mm YM-04054 Middle gear backlash tool 90890-04080 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-01304 YM-04054 YU-24460-01 1-41 SPECIAL TOOLS 5-82 5-109, 5-111 5-110 5-113 6-4 Reference pages
Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 Mechanical seal installer 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 90890-04058 Bearing driver 40 mm YM-04058 Pressure gauge 90890-03153 YU-03153 Tool name/Tool No. Illustration Fuel pressure adapter 90890-03176 YM-03176 Fuel injector pressure adapter 90890-03210 YU-03210 Ignition checker 90890-06754 Opama pet-4000 spark checker YM-34487 Test harness-speed sensor (3P) 90890-03208 YU-03208 YU-33984 1-42 SPECIAL TOOLS 6-4 6-13 6-13 7-5, 7-14 7-5 7-14 Reference pages 8-132 8-139
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 and 44: EAS20180 IMPORTANT INFORMATION EAS2
Page 45 and 46: EAS20250 CHECKING THE CONNECTIONS C
Page 47 and 48: Oil filter wrench 90890-01426 YU-38
Page 49: Valve guide installer (ø5) 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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