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7. Check: • Pinion gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat “1” TIP Align the projection “a” on the starter motor rear cover with the slot “b” in the brush seat. 2. Install: • Starter motor yoke “1” • Starter motor rear cover “2” a TIP Align the projection “a” on the starter motor rear cover with the slot “b” in the starter motor yoke. 1 b a 2 1 b 5-47 ELECTRIC STARTER 3. Install: • Starter motor yoke “1” • Starter motor front cover “2” TIP Align the match marks “a” on the starter motor yoke with the match mark “b” on the starter motor front cover. b 2 1 a
EAS25061 CLUTCH Removing the clutch cover (5) T.R. 1 Order Job/Parts to remove Q’ty Remarks Engine oil 5 12 Nm (1.2 m•kgf, 8.7 ft•Ibf) New 2 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Clutch cover damper plate 1 5 Clutch cover damper 1 4 5-48 LT (5) T.R. 3 10 Nm (1.0 m•kgf, 7.2 ft•Ibf) CLUTCH Drain. Refer to “CHANGING THE ENGINE OIL” on page 3-11. For installation, reverse the removal procedure.
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SERVICE MANUAL VMX17Y(C) 2009 LIT-1
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EAS20071 IMPORTANT This manual was
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EAS20100 SYMBOLS The following symb
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GENERAL INFORMATION IDENTIFICATION
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EAS20170 FEATURES 1-2 FEATURES EAS3
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1-4 FEATURES EAS2S31084 OUTLINE OF
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a. Friction force between the tire
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a. Friction force between the tire
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1-10 FEATURES The front and rear se
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1 2 1-12 FEATURES Buffer chamber Th
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1-14 FEATURES TIP Some types of mal
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1-16 FEATURES Emergency braking (AB
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1-18 FEATURES Instances when the AB
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EAS2S31088 ABS WARNING LIGHT AND OP
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1-22 FEATURES EAS2S31089 YCC-T (YAM
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YCC-T/YCC-I system outline 1 13 14
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EAS2S31097 INSTRUMENT FUNCTIONS 1.
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2. Push “RESET”. 3. Push “SEL
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1. Push “SELECT” to highlight
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If, when the engine is running whil
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EAS20180 IMPORTANT INFORMATION EAS2
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EAS20250 CHECKING THE CONNECTIONS C
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Oil filter wrench 90890-01426 YU-38
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Valve guide installer (ø5) 90890-0
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Radiator cap tester adapter 90890-0
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SPECIFICATIONS GENERAL SPECIFICATIO
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EAS20290 ENGINE SPECIFICATIONS 2-2
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2-4 ENGINE SPECIFICATIONS Exhaust B
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2-6 ENGINE SPECIFICATIONS Cylinder
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Primary reduction ratio 86/57 (1.50
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EAS20300 CHASSIS SPECIFICATIONS Cha
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Standard 4 Maximum 1 Rebound dampin
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Engine trouble warning light LED AB
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EAS20320 TIGHTENING TORQUES EAS2033
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Item Thread size 2-18 TIGHTENING TO
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Crankcase tightening sequence A 15
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Shift forks and shift fork guide ba
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LUBRICATION POINTS AND LUBRICANT TY
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1. Oil pan 2. Oil strainer 3. Oil p
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1. Timing chain tensioner (rear cyl
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1. Balancer shaft 2. Main axle 3. D
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1. Crankshaft 2. Main gallery bolt
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1. Oil filter cartridge 2. Oil nozz
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1. Thermostat inlet pipe (rear cyli
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1. Thermostat outlet hose 2. Upper
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1. Front brake light switch lead 2.
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1. Throttle cables 2. Brake hose (f
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1. Meter assembly 2 coupler 2. Igni
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1. Radiator fan motor relay 2. Head
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1. Meter assembly 2 2. Main switch
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1. ABS test coupler 2. Fuel tank br
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1. Meter assembly 1 lead 2. Upper r
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1. Fuel pump coupler 2. Rear left t
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1. ECU (engine control unit) 2. Wir
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1. Accelerator position sensor 2. T
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1. Brake hose (hydraulic unit to le
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1. Clutch hose 2. Brake hose (hydra
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PERIODIC CHECKS AND ADJUSTMENTS PER
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EAS20450 PERIODIC MAINTENANCE 3-1 P
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No. ITEM ROUTINE 25 Final gear oil
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. Turn the crankshaft almost 1/2 of
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2 1 g. Install the exhaust and inta
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EAS20630 ADJUSTING THE THROTTLE CAB
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EAS20780 CHANGING THE ENGINE OIL 1.
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a ▲▲▲▲▲▲▲▲▲▲▲
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ECA2S31058 NOTICE Never operate the
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17 18 8 4 15 16 5 20 9 3 9 14 14 8
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• Upper radiator inlet pipe “3
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13.Install: • Coolant reservoir c
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TIP In order to ensure a correct re
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ECA2S31005 NOTICE Make sure that th
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. Loosen the lower ring nut “4”
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Rebound damping ECA13590 NOTICE Nev
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Compression damping adjusting posit
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3. Check: • Wheel bearings Refer
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▼▼▼▼▼▼▼▼▼▼▼
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REAR BRAKE ........................
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EAS21830 GENERAL CHASSIS Removing t
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4-3 GENERAL CHASSIS Removing the si
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Removing the passenger footrests an
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Disassembling the intake duct assem
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Removing the battery T.R. 10 Nm (1.
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Removing the meter assembly 1 and h
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Disassembling the front wheel New 1
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• Front wheel Damage/wear → Rep
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ECA2S31010 NOTICE Replace the wheel
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d. In the order pinch bolt “3”
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Removing the rear wheel, brake disc
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EAS22050 REMOVING THE REAR WHEEL (D
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1. Install: • Bearing “1” 2.
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5. Tighten: • Rear wheel axle •
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EAS22210 FRONT BRAKE Removing the f
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Disassembling the front brake maste
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Disassembling the front brake calip
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d. Measure the brake disc deflectio
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EAS22390 CHECKING THE FRONT BRAKE C
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TIP To collect any remaining brake
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EAS22550 REAR BRAKE Removing the re
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Removing the rear brake master cyli
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Removing the rear brake caliper T.R
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EAS22560 INTRODUCTION EWA14100 WARN
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EAS22600 DISASSEMBLING THE REAR BRA
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▲▲▲▲▲▲▲▲▲▲▲
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2. Install: • Brake hose gaskets
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EAS22760 ABS (ANTI-LOCK BRAKE SYSTE
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EAS2S31023 REMOVING THE HYDRAULIC U
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6. Fill: • Brake master cylinder
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5. Connect the test coupler adapter
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EAS22840 HANDLEBAR Removing the han
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EAS22860 REMOVING THE HANDLEBAR 1.
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TIP • Align the mating surfaces o
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Removing the front fork legs LT T.R
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Disassembling the front fork legs T
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TIP While holding the damper rod wi
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6. Install: • Oil seal “1” (w
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a. More than 12 mm (0.47 in) ▲▲
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Removing the coupler holder and bra
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EAS23110 REMOVING THE LOWER BRACKET
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EAS23160 REAR SHOCK ABSORBER ASSEMB
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EAS23170 HANDLING THE REAR SHOCK AB
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TIP • Hold the connecting arm and
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EAS23350 REMOVING THE SWINGARM 1. S
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EAS23551 SHAFT DRIVE Removing the f
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Disassembling the final drive assem
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EAS23560 TROUBLESHOOTING 4-95 SHAFT
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4. Measure: • Final gear backlash
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4. Remove: • Bearing retainer (wi
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Final drive pinion gear shims Thick
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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 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
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TIP • Align the projections “a
Page 372 and 373:
Disassembling the main axle assembl
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Disassembling the drive axle/middle
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3. Check: • Transmission gears Bl
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EAS25711 MIDDLE GEAR Removing the m
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Removing the middle drive pinion ge
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EAS2S31047 REMOVING THE MIDDLE DRIV
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TIP While compressing the spring wi
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2 ▲▲▲▲▲▲▲▲▲▲▲
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TIP Select the middle driven pinion
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5-117 MIDDLE GEAR
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EAS2S31078 RADIATORS Removing the r
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Disassembling the radiators T.R. T.
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EAS26410 OIL COOLER Removing the oi
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EAS26440 THERMOSTAT Removing the th
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EAS26450 CHECKING THE THERMOSTAT 1.
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EAS26500 WATER PUMP Removing the wa
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EAS26510 DISASSEMBLING THE WATER PU
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6-15 WATER PUMP
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EAS26620 FUEL TANK Removing the fue
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EAS26630 REMOVING THE FUEL TANK 1.
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c. Connect the pressure gauge “2
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Removing the air filter case and in
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1 EAS2S31007 INSTALLING THE AIR FIL
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EAS26970 THROTTLE BODIES Removing t
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Removing the injectors T.R. 3.5 Nm
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Pressure drops → Properly install
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2. Adjust: • Throttle position se
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EAS27040 AIR INDUCTION SYSTEM B 6 6
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Removing the air cut-off valve asse
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EAS27060 CHECKING THE AIR INDUCTION
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ABS (ANTI-LOCK BRAKE SYSTEM).......
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6. Main fuse 7. Main switch 8. Batt
Page 437 and 438:
EAS27140 TROUBLESHOOTING The igniti
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8-6 IGNITION SYSTEM
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EAS27190 TROUBLESHOOTING The starte
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8-12 ELECTRIC STARTING SYSTEM
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1. AC magneto 2. Rectifier/regulato
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8-16 CHARGING SYSTEM
Page 451 and 452:
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7. Check the entire lighting system
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Page 457 and 458:
2. Check the horn. Refer to “CHEC
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2. Check the entire signaling syste
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8-28 SIGNALING SYSTEM
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Page 465 and 466:
8-32 COOLING SYSTEM
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3. Fuel injection system fuse 5. El
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a. Main switch “OFF” b. Main sw
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8-38 FUEL INJECTION SYSTEM • To i
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Diagnostic code No. D:60 EEPROM fau
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Diagnostic code No. D:39 Injector #
Page 477 and 478:
8-44 FUEL INJECTION SYSTEM Fault co
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Fault code No. 15 D:13 Meter displa
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Fault code No. 19 Item Fail-safe sy
Page 483 and 484:
Fault code No. 22 8-50 FUEL INJECTI
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Fault code No. 30 Item Fail-safe sy
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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
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8-68 FUEL INJECTION SYSTEM
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3. Fuel injection system fuse 6. Ma
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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
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ABS (ANTI-LOCK BRAKE SYSTEM) • If
Page 519 and 520:
Fault code No. ABS-22 ABS-24 ABS-31
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Fault code No. ABS-11 ABS-25 Order
Page 523 and 524:
Page 525 and 526:
ABS (ANTI-LOCK BRAKE SYSTEM) Fault
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Page 529 and 530:
Page 531 and 532:
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Page 541 and 542:
Page 543 and 544:
Page 545 and 546:
Page 547 and 548:
EAS2S31075 [D-1] DELETING THE FAULT
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ABS (ANTI-LOCK BRAKE SYSTEM) 8-116
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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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