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Yamaha Manuals
Motorcycle
VMAX 2009
Service manual
Yamaha VMAX 2009 Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
Table of Contents
General Information
Identification
Vehicle Identification Number
Model Label
Features
Outline of the Fi System
Fi System
Outline of the Abs
Abs Component Functions
Abs Operation
Abs Self-Diagnosis Function
Abs Warning Light and Operation
Ycc-T (Yamaha Chip Controlled Throttle)/Ycc-I (Yamaha Chip Controlled Intake)
Instrument Functions
Important Information
Preparation for Removal and Disassembly
Replacement Parts
Gaskets, Oil Seals and O-Rings
Lock Washers/Plates and Cotter Pins
Bearings and Oil Seals
Circlips
Checking the Connections
Special Tools
Specifications
General Specifications
Engine Specifications
Chassis Specifications
Electrical Specifications
Tightening Torques
General Tightening Torque Specifications
Engine Tightening Torques
Chassis Tightening Torques
Lubrication Points and Lubricant Types
Engine
Chassis
Lubrication System Chart and Diagrams
Engine Oil Lubrication Chart
Lubrication Diagrams
Cooling System Diagrams
Cable Routing
Periodic Checks and Adjustments
Periodic Maintenance
Introduction
Engine
Adjusting the Valve Clearance
Synchronizing the Throttle Bodies
Adjusting the Exhaust Gas Volume
Adjusting the Throttle Cable Free Play
Checking the Spark Plugs
Checking the Engine Oil Level
Changing the Engine Oil
Measuring the Engine Oil Pressure
Adjusting the Clutch Lever
Checking the Clutch Fluid Level
Bleeding the Hydraulic Clutch System
Replacing the Air Filter Element
Checking the Throttle Body Joints
Checking the Fuel Line
Checking the Cylinder Head Breather Hose
Checking the Crankcase Breather Hose
Checking the Exhaust System
Adjusting the Exup Cables
Checking the Coolant Level
Checking the Cooling System
Changing the Coolant
Checking the Air Induction System
Chassis
Adjusting the Front Disc Brake
Checking the Brake Fluid Level
Checking the Front Brake Pads
Checking the Rear Brake Pads
Checking the Brake Hoses
Checking the Brake Light Switches
Adjusting the Rear Brake Light Switch
Bleeding the Hydraulic Brake System (Abs)
Adjusting the Shift Pedal
Checking the Final Gear Oil Level
Changing the Final Gear Oil
Checking and Adjusting the Steering Head
Checking the Front Fork
Checking the Rear Suspension
Checking the Swingarm Pivot
Adjusting the Front Fork Legs
Adjusting the Rear Shock Absorber Assembly
Checking the Tires
Checking the Wheels
Checking the Sidestand
Checking and Lubricating the Cables
Lubricating the Levers
Lubricating the Pedals
Lubricating the Sidestand
Lubricating the Rear Suspension
Lubricating the Swingarm Pivot
Lubricating the Steering Head
Checking the Fasteners
Electrical System
Checking and Charging the Battery
Checking the Fuses
Replacing the Headlight Bulb
Adjusting the Headlight Beam
Checking the Switches, Lights and Signals
Checking the Switches
General Chassis
Installing the Abs Test Coupler
Installing the Top Cover
Installing the Battery
Front Wheel
Removing the Front Wheel
Disassembling the Front Wheel
Checking the Front Wheel
Maintenance of the Front Wheel Sensor and Sensor Rotor
Assembling the Front Wheel
Adjusting the Front Wheel Static Balance
Installing the Front Wheel (Front Brake Discs)
Rear Wheel
Removing the Rear Wheel (Disc)
Disassembling the Rear Wheel
Checking the Rear Wheel
Maintenance of the Rear Wheel Sensor and Sensor Rotor
Assembling the Rear Wheel
Adjusting the Rear Wheel Static Balance
Installing the Rear Wheel (Rear Brake Disc)
Front Brake
Introduction
Checking the Front Brake Discs
Replacing the Front Brake Pads
Removing the Front Brake Calipers
Disassembling the Front Brake Calipers
Checking the Front Brake Calipers
Assembling the Front Brake Calipers
Installing the Front Brake Calipers
Removing the Front Brake Master Cylinder
Checking the Front Brake Master Cylinder
Assembling the Front Brake Master Cylinder
Installing the Front Brake Master Cylinder
Rear Brake
Introduction
Checking the Rear Brake Disc
Replacing the Rear Brake Pads
Removing the Rear Brake Caliper
Disassembling the Rear Brake Caliper
Checking the Rear Brake Caliper
Assembling the Rear Brake Caliper
Installing the Rear Brake Caliper
Removing the Rear Brake Master Cylinder
Checking the Rear Brake Master Cylinder
Assembling the Rear Brake Master Cylinder
Installing the Rear Brake Master Cylinder
Abs (Anti-Lock Brake System)
Abs Components Chart
Removing the Hydraulic Unit Assembly
Checking the Hydraulic Unit Assembly
Checking the Brake Hoses
Installing the Hydraulic Unit Assembly
Hydraulic Unit Operation Tests
Trial Run
Handlebar
Removing the Handlebar
Checking the Handlebar
Installing the Handlebar
Front Fork
Removing the Front Fork Legs
Disassembling the Front Fork Legs
Checking the Front Fork Legs
Assembling the Front Fork Legs
Installing the Front Fork Legs
Steering Head
Removing the Lower Bracket
Checking the Steering Head
Installing the Steering Head
Rear Shock Absorber Assembly
Handling the Rear Shock Absorber and Gas Cylinder
Disposing of a Rear Shock Absorber
Removing the Rear Shock Absorber Assembly
Checking the Rear Shock Absorber Assembly and Gas Cylinder
Checking the Connecting Arm and Relay Arm
Installing the Rear Shock Absorber Assembly
Swingarm
Removing the Swingarm
Checking the Swingarm
Installing the Swingarm
Shaft Drive
Troubleshooting
Checking the Final Gear Oil for Contamination and Checking the Shaft Drive for Leaks
Measuring the Final Gear Backlash
Adjusting the Final Gear Backlash
Disassembling the Final Drive Assembly
Removing and Installing the Bearing
Assembling the Final Drive Assembly
Aligning the Final Drive Pinion Gear and Ring Gear
Checking the Drive Shaft
Installing the Final Drive Assembly
Engine
Engine Removal
Installing the Engine
Installing the Exup Cables
Camshafts
Removing the Camshafts
Checking the Camshafts
Checking the Camshaft Sprockets
Checking the Camshaft Gears
Checking the Decompression System
Checking the Timing Chain Guides
Checking the Timing Chain Tensioners
Installing the Camshafts
Cylinder Heads
Removing the Cylinder Heads
Checking the Cylinder Heads
Installing the Cylinder Heads
Valves and Valve Springs
Removing the Valves
Checking the Valves and Valve Guides
Checking the Valve Seats
Checking the Valve Springs
Checking the Valve Lifters
Installing the Valves
Generator and Starter Clutch
Removing the Generator
Removing the Starter Clutch
Checking the Starter Clutch
Installing the Starter Clutch
Installing the Generator
Electric Starter
Checking the Starter Motor
Assembling the Starter Motor
Clutch
Removing the Clutch
Checking the Friction Plates
Checking the Clutch Plates
Checking the Clutch Spring Plate
Checking the Clutch Housing
Checking the Clutch Boss
Checking the Pressure Plate
Checking the Clutch Push Rods
Checking the Primary Driven Gear
Installing the Clutch
Disassembling the Clutch Master Cylinder
Checking the Clutch Master Cylinder
Assembling the Clutch Master Cylinder
Installing the Clutch Master Cylinder
Removing the Clutch Release Cylinder
Checking the Clutch Release Cylinder
Assembling the Clutch Release Cylinder
Installing the Clutch Release Cylinder
Shift Shaft
Checking the Shift Shaft
Checking the Stopper Lever
Installing the Shift Shaft
Oil Pump
Removing the Oil Pan
Checking the Oil Pump
Checking the Relief Valve
Checking the Oil Pipe 2
Checking the Oil Strainer
Assembling the Oil Pump
Installing the Oil Pump
Installing the Oil Pan
Crankcase
Disassembling the Crankcase
Checking the Crankcase
Checking the Oil Pipe 3
Checking the Timing Chain Guide Assembly
Checking the Oil Nozzles
Assembling the Crankcase
Connecting Rods and Pistons
Removing the Connecting Rods and Pistons
Checking the Oil Nozzles
Checking the Cylinders and Pistons
Checking the Piston Rings
Checking the Piston Pins
Checking the Connecting Rods
Installing the Connecting Rods and Pistons
Crankshaft and Balancer
Removing the Balancer Shaft Journal Bearings
Removing the Crankshaft Journal Bearings
Checking the Timing Chains
Checking the Crankshaft
Checking the Balancer
Installing the Crankshaft
Installing the Balancer Shaft
Transmission
Checking the Shift Forks
Checking the Shift Drum Assembly
Checking the Transmission
Assembling the Main Axle and Drive Axle
Installing the Transmission
Middle Gear
Removing the Middle Driven Pinion Gear Assembly
Disassembling the Middle Driven Pinion Gear Assembly
Removing the Middle Drive Pinion Gear Assembly
Disassembling the Middle Drive Pinion Gear Assembly
Checking the Middle Driven Pinion Gear Assembly
Checking the Middle Drive Pinion Gear Assembly
Assembling the Middle Drive Pinion Gear Assembly
Installing the Middle Drive Pinion Gear Assembly
Assembling the Middle Driven Pinion Gear Assembly
Installing the Middle Driven Pinion Gear Assembly
Measuring the Middle Gear Backlash
Adjusting the Middle Gear Backlash
Aligning the Middle Gear
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2009
SERVICE MANUAL
VMX17(Y)
2S3-28197-E0
Table of
Contents
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Table of Contents
Troubleshooting
TROUBLESHOOTING
260
TROUBLESHOOTING
437
TROUBLESHOOTING
443
TROUBLESHOOTING
448
TROUBLESHOOTING
452
TROUBLESHOOTING
456
TROUBLESHOOTING
464
TROUBLESHOOTING METHOD
469
TROUBLESHOOTING DETAILS
476
TROUBLESHOOTING
504
TROUBLESHOOTING
511
MAINTENANCE OF THE ABS ECU
520
BASIC INSTRUCTIONS FOR TROUBLESHOOTING
521
BASIC PROCESS FOR TROUBLESHOOTING
522
TROUBLESHOOTING
583
TROUBLESHOOTING
584
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This manual is also suitable for:
Vmx17 2009
Vmx17y 2009
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