Yamaha VMX17 2009 Manuals

Manuals and User Guides for Yamaha VMX17 2009. We have 1 Yamaha VMX17 2009 manual available for free PDF download: Service Manual

Yamaha VMX17 2009 Service Manual

Yamaha VMX17 2009 Service Manual (592 pages)

Brand: Yamaha | Category: Motorcycle | Size: 45.74 MB

Table of Contents

Table of Contents
7
General Information
9
- Identification
  10
- Vehicle Identification Number
  10
- Model Label
  10
- Features
  11
- Outline of the Fi System
  11
- Fi System
  12
- Outline of the Abs
  13
- Abs Component Functions
  18
- Abs Operation
  23
- Abs Self-Diagnosis Function
  26
- Abs Warning Light and Operation
  29
- Ycc-T (Yamaha Chip Controlled Throttle)/Ycc-I (Yamaha Chip Controlled Intake)
  31
- Instrument Functions
  35
- Important Information
  43
- Preparation for Removal and Disassembly
  43
- Replacement Parts
  43
- Gaskets, Oil Seals and O-Rings
  43
- Lock Washers/Plates and Cotter Pins
  43
- Bearings and Oil Seals
  44
- Circlips
  44
- Checking the Connections
  45
- Special Tools
  46
Specifications
53
- General Specifications
  54
- Engine Specifications
  55
- Chassis Specifications
  63
- Electrical Specifications
  66
- Tightening Torques
  69
- General Tightening Torque Specifications
  69
- Engine Tightening Torques
  70
- Chassis Tightening Torques
  76
- Lubrication Points and Lubricant Types
  82
- Engine
  82
- Chassis
  84
- Lubrication System Chart and Diagrams
  86
- Engine Oil Lubrication Chart
  86
- Lubrication Diagrams
  88
- Cooling System Diagrams
  96
- Cable Routing
  100
Periodic Checks and Adjustments
125
- Periodic Maintenance
  128
- Introduction
  128
- Engine
  131
- Adjusting the Valve Clearance
  131
- Synchronizing the Throttle Bodies
  134
- Adjusting the Exhaust Gas Volume
  136
- Adjusting the Throttle Cable Free Play
  136
- Checking the Spark Plugs
  137
- Checking the Engine Oil Level
  138
- Changing the Engine Oil
  138
- Measuring the Engine Oil Pressure
  139
- Adjusting the Clutch Lever
  140
- Checking the Clutch Fluid Level
  140
- Bleeding the Hydraulic Clutch System
  141
- Replacing the Air Filter Element
  142
- Checking the Throttle Body Joints
  143
- Checking the Fuel Line
  143
- Checking the Cylinder Head Breather Hose
  143
- Checking the Crankcase Breather Hose
  143
- Checking the Exhaust System
  144
- Adjusting the Exup Cables
  145
- Checking the Coolant Level
  146
- Checking the Cooling System
  146
- Changing the Coolant
  147
- Checking the Air Induction System
  148
Chassis
149
- Adjusting the Front Disc Brake
  149
- Checking the Brake Fluid Level
  149
- Checking the Front Brake Pads
  150
- Checking the Rear Brake Pads
  150
- Checking the Brake Hoses
  150
- Checking the Brake Light Switches
  150
- Adjusting the Rear Brake Light Switch
  150
- Bleeding the Hydraulic Brake System (Abs)
  151
- Adjusting the Shift Pedal
  152
- Checking the Final Gear Oil Level
  152
- Changing the Final Gear Oil
  153
- Checking and Adjusting the Steering Head
  153
- Checking the Front Fork
  154
- Checking the Rear Suspension
  155
- Checking the Swingarm Pivot
  155
- Adjusting the Front Fork Legs
  155
- Adjusting the Rear Shock Absorber Assembly
  156
- Checking the Tires
  158
- Checking the Wheels
  159
- Checking the Sidestand
  160
- Checking and Lubricating the Cables
  160
- Lubricating the Levers
  160
- Lubricating the Pedals
  160
- Lubricating the Sidestand
  160
- Lubricating the Rear Suspension
  160
- Lubricating the Swingarm Pivot
  160
- Lubricating the Steering Head
  160
- Checking the Fasteners
  160
- Electrical System
  161
- Checking and Charging the Battery
  161
- Checking the Fuses
  161
- Replacing the Headlight Bulb
  161
- Adjusting the Headlight Beam
  161
- Checking the Switches, Lights and Signals
  162
- Checking the Switches
  162
- General Chassis
  166
- Installing the Abs Test Coupler
  169
- Installing the Top Cover
  173
- Installing the Battery
  175
- Front Wheel
  177
- Removing the Front Wheel
  179
- Disassembling the Front Wheel
  179
- Checking the Front Wheel
  179
- Maintenance of the Front Wheel Sensor and Sensor Rotor
  180
- Assembling the Front Wheel
  181
- Adjusting the Front Wheel Static Balance
  182
- Installing the Front Wheel (Front Brake Discs)
  183
- Rear Wheel
  185
- Removing the Rear Wheel (Disc)
  188
- Disassembling the Rear Wheel
  188
- Checking the Rear Wheel
  189
- Maintenance of the Rear Wheel Sensor and Sensor Rotor
  189
- Assembling the Rear Wheel
  189
- Adjusting the Rear Wheel Static Balance
  191
- Installing the Rear Wheel (Rear Brake Disc)
  191
- Front Brake
  194
- Introduction
  199
- Checking the Front Brake Discs
  199
- Replacing the Front Brake Pads
  200
- Removing the Front Brake Calipers
  201
- Disassembling the Front Brake Calipers
  201
- Checking the Front Brake Calipers
  202
- Assembling the Front Brake Calipers
  202
- Installing the Front Brake Calipers
  202
- Removing the Front Brake Master Cylinder
  203
- Checking the Front Brake Master Cylinder
  204
- Assembling the Front Brake Master Cylinder
  204
- Installing the Front Brake Master Cylinder
  204
- Rear Brake
  206
- Introduction
  212
- Checking the Rear Brake Disc
  212
- Replacing the Rear Brake Pads
  212
- Removing the Rear Brake Caliper
  213
- Disassembling the Rear Brake Caliper
  214
- Checking the Rear Brake Caliper
  214
- Assembling the Rear Brake Caliper
  214
- Installing the Rear Brake Caliper
  215
- Removing the Rear Brake Master Cylinder
  217
- Checking the Rear Brake Master Cylinder
  217
- Assembling the Rear Brake Master Cylinder
  217
- Installing the Rear Brake Master Cylinder
  217
- Abs (Anti-Lock Brake System)
  220
- Abs Components Chart
  220
- Removing the Hydraulic Unit Assembly
  222
- Checking the Hydraulic Unit Assembly
  222
- Checking the Brake Hoses
  222
- Installing the Hydraulic Unit Assembly
  223
- Hydraulic Unit Operation Tests
  224
- Trial Run
  227
- Handlebar
  228
- Removing the Handlebar
  230
- Checking the Handlebar
  230
- Installing the Handlebar
  230
- Front Fork
  233
- Removing the Front Fork Legs
  237
- Disassembling the Front Fork Legs
  237
- Checking the Front Fork Legs
  238
- Assembling the Front Fork Legs
  238
- Installing the Front Fork Legs
  242
- Steering Head
  243
- Removing the Lower Bracket
  246
- Checking the Steering Head
  246
- Installing the Steering Head
  246
- Rear Shock Absorber Assembly
  248
- Handling the Rear Shock Absorber and Gas Cylinder
  250
- Disposing of a Rear Shock Absorber
  250
- Removing the Rear Shock Absorber Assembly
  250
- Checking the Rear Shock Absorber Assembly and Gas Cylinder
  250
- Checking the Connecting Arm and Relay Arm
  250
- Installing the Rear Shock Absorber Assembly
  251
- Swingarm
  253
- Removing the Swingarm
  254
- Checking the Swingarm
  254
- Installing the Swingarm
  254
- Shaft Drive
  256
- Troubleshooting
  260
- Checking the Final Gear Oil for Contamination and Checking the Shaft Drive for Leaks
  261
- Measuring the Final Gear Backlash
  261
- Adjusting the Final Gear Backlash
  262
- Disassembling the Final Drive Assembly
  263
- Removing and Installing the Bearing
  264
- Assembling the Final Drive Assembly
  264
- Aligning the Final Drive Pinion Gear and Ring Gear
  265
- Checking the Drive Shaft
  268
- Installing the Final Drive Assembly
  268
Engine
271
- Engine Removal
  274
- Installing the Engine
  280
- Installing the Exup Cables
  281
- Camshafts
  282
- Removing the Camshafts
  286
- Checking the Camshafts
  287
- Checking the Camshaft Sprockets
  288
- Checking the Camshaft Gears
  289
- Checking the Decompression System
  289
- Checking the Timing Chain Guides
  289
- Checking the Timing Chain Tensioners
  289
- Installing the Camshafts
  290
- Cylinder Heads
  299
- Removing the Cylinder Heads
  300
- Checking the Cylinder Heads
  300
- Installing the Cylinder Heads
  300
- Valves and Valve Springs
  303
- Removing the Valves
  303
- Checking the Valves and Valve Guides
  303
- Checking the Valve Seats
  305
- Checking the Valve Springs
  307
- Checking the Valve Lifters
  307
- Installing the Valves
  307
- Generator and Starter Clutch
  310
- Removing the Generator
  313
- Removing the Starter Clutch
  313
- Checking the Starter Clutch
  313
- Installing the Starter Clutch
  314
- Installing the Generator
  314
- Electric Starter
  317
- Checking the Starter Motor
  319
- Assembling the Starter Motor
  320
- Clutch
  327
- Removing the Clutch
  329
- Checking the Friction Plates
  329
- Checking the Clutch Plates
  330
- Checking the Clutch Spring Plate
  331
- Checking the Clutch Housing
  331
- Checking the Clutch Boss
  331
- Checking the Pressure Plate
  331
- Checking the Clutch Push Rods
  331
- Checking the Primary Driven Gear
  331
- Installing the Clutch
  332
- Disassembling the Clutch Master Cylinder
  333
- Checking the Clutch Master Cylinder
  334
- Assembling the Clutch Master Cylinder
  334
- Installing the Clutch Master Cylinder
  334
- Removing the Clutch Release Cylinder
  335
- Checking the Clutch Release Cylinder
  335
- Assembling the Clutch Release Cylinder
  336
- Installing the Clutch Release Cylinder
  336
- Shift Shaft
  338
- Checking the Shift Shaft
  340
- Checking the Stopper Lever
  340
- Installing the Shift Shaft
  340
- Oil Pump
  341
- Removing the Oil Pan
  344
- Checking the Oil Pump
  344
- Checking the Relief Valve
  344
- Checking the Oil Pipe 2
  345
- Checking the Oil Strainer
  345
- Assembling the Oil Pump
  345
- Installing the Oil Pump
  345
- Installing the Oil Pan
  345
- Crankcase
  346
- Disassembling the Crankcase
  349
- Checking the Crankcase
  349
- Checking the Oil Pipe 3
  349
- Checking the Timing Chain Guide Assembly
  350
- Checking the Oil Nozzles
  350
- Assembling the Crankcase
  350
- Connecting Rods and Pistons
  354
- Removing the Connecting Rods and Pistons
  355
- Checking the Oil Nozzles
  355
- Checking the Cylinders and Pistons
  355
- Checking the Piston Rings
  356
- Checking the Piston Pins
  357
- Checking the Connecting Rods
  358
- Installing the Connecting Rods and Pistons
  361
- Crankshaft and Balancer
  365
- Removing the Balancer Shaft Journal Bearings
  366
- Removing the Crankshaft Journal Bearings
  366
- Checking the Timing Chains
  366
- Checking the Crankshaft
  366
- Checking the Balancer
  368
- Installing the Crankshaft
  369
- Installing the Balancer Shaft
  370
- Transmission
  371
- Checking the Shift Forks
  375
- Checking the Shift Drum Assembly
  375
- Checking the Transmission
  375
- Assembling the Main Axle and Drive Axle
  376
- Installing the Transmission
  377
- Middle Gear
  379
- Removing the Middle Driven Pinion Gear Assembly
  382
- Disassembling the Middle Driven Pinion Gear Assembly
  382
- Removing the Middle Drive Pinion Gear Assembly
  382
- Disassembling the Middle Drive Pinion Gear Assembly
  382
- Checking the Middle Driven Pinion Gear Assembly
  383
- Checking the Middle Drive Pinion Gear Assembly
  383
- Assembling the Middle Drive Pinion Gear Assembly
  383
- Installing the Middle Drive Pinion Gear Assembly
  383
- Assembling the Middle Driven Pinion Gear Assembly
  384
- Installing the Middle Driven Pinion Gear Assembly
  385
- Measuring the Middle Gear Backlash
  386
- Adjusting the Middle Gear Backlash
  386
- Aligning the Middle Gear
  387
Cooling System
391
- Radiators
  392
- Checking the Radiators
  395
- Installing the Radiator Assembly
  395
- Oil Cooler
  397
- Checking the Oil Cooler
  397
- Installing the Oil Cooler
  397
- Thermostat
  398
- Checking the Thermostat
  400
- Installing the Thermostat Assembly
  400
- Water Pump
  402
- Disassembling the Water Pump
  404
- Checking the Water Pump
  404
- Assembling the Water Pump
  404
- Installing the Water Pump
  405
Fuel System
407
- Fuel Tank
  408
- Removing the Fuel Tank
  410
- Removing the Fuel Pump
  410
- Checking the Fuel Pump Body
  410
- Checking the Rollover Valve
  410
- Installing the Fuel Pump
  410
- Installing the Filler Neck
  411
- Installing the Fuel Tank
  411
- Checking the Fuel Pressure
  411
- Air Filter Case
  413
- Checking the Intake Funnels
  415
- Removing the Air Filter Case and Intake Funnels
  415
- Installing the Air Filter Case and Intake Funnels
  416
- Throttle Bodies
  418
- Checking the Injectors
  420
- Installing the Injectors
  420
- Checking the Injector Pressure
  420
- Checking and Cleaning the Throttle Bodies
  421
- Adjusting the Throttle Position Sensor
  422
- Adjusting the Accelerator Position Sensor
  423
- Air Induction System
  426
- Checking the Air Induction System
  430
Electrical System
431
- Ignition System
  434
- Circuit Diagram
  434
- Engine Stopping Due to Sidestand Operation
  436
- Troubleshooting
  437
- Electric Starting System
  440
- Circuit Diagram
  440
- Starting Circuit Cut-Off System Operation
  442
- Troubleshooting
  443
- Charging System
  446
- Circuit Diagram
  446
- Troubleshooting
  448
- Lighting System
  450
- Circuit Diagram
  450
- Troubleshooting
  452
- Signaling System
  454
- Circuit Diagram
  454
- Troubleshooting
  456
- Cooling System
  462
- Circuit Diagram
  462
- Troubleshooting
  464
- Fuel Injection System
  466
- Circuit Diagram
  466
- Ecu Self-Diagnostic Function
  468
- Troubleshooting Method
  469
- Diagnostic Mode
  470
- Troubleshooting Details
  476
- Fuel Pump System
  502
- Circuit Diagram
  502
- Troubleshooting
  504
- Immobilizer System
  506
- Circuit Diagram
  506
- General Information
  508
- Part Replacement and Key Code Registration Requirements
  508
- Troubleshooting
  511
- Self-Diagnosis Fault Code Indication
  512
- Abs (Anti-Lock Brake System)
  514
- Circuit Diagram
  514
- Abs Components Chart
  516
- Abs Coupler Location Chart
  518
- Maintenance of the Abs Ecu
  520
- Abs Troubleshooting Outline
  520
- Basic Instructions for Troubleshooting
  521
- Basic Process for Troubleshooting
  522
- [A] Checking the Abs Warning Light
  523
- [B-1] the Abs Warning Light Fails to Come on
  523
- [B-2] the Abs Warning Light Flashes
  523
- [B-3] the Abs Warning Light Remains on
  523
- [B-4] the Abs Warning Light Comes on for 2 Seconds, then Goes off
  523
- [B-5] Malfunction Are Currently Detected
  524
- [C-1] Only the Abs Warning Light Fails to Come on
  524
- [C-2] All Indicator Lights Fail to Come on
  524
- [C-3] the Abs Warning Light Remains on
  525
- [C-4] the Abs Warning Light Flashes
  525
- [C-5] Diagnosis Using the Fault Codes
  526
- [D-1] Deleting the Fault Codes
  555
- [D-2] Delete Function Test
  555
- [D-3] Final Check
  556
- Electrical Components
  558
- Checking the Switches
  562
- Checking the Bulbs and Bulb Sockets
  565
- Checking the Fuses
  566
- Checking and Charging the Battery
  567
- Checking the Relays
  570
- Checking the Turn Signal/Hazard Relay
  571
- Checking the Relay Unit (Diode)
  571
- Checking the Ignition Coils
  572
- Checking the Ignition Spark Gap
  573
- Checking the Crankshaft Position Sensor
  573
- Checking the Lean Angle Sensor
  574
- Checking the Starter Motor Operation
  574
- Checking the Stator Coil
  575
- Checking the Rectifier/Regulator
  575
- Checking the Horn
  575
- Checking the Oil Level Switch
  576
- Checking the Fuel Sender
  576
- Checking the Fuel Level Warning Light
  577
- Checking the Oil Level Warning Light
  577
- Checking the Radiator Fan Motors
  577
- Checking the Coolant Temperature Sensor
  577
- Checking the Throttle Position Sensor
  578
- Checking the Accelerator Position Sensor
  579
- Checking the Air Induction System Solenoid
  579
- Checking the Atmospheric Pressure Sensor
  579
- Checking the Cylinder Identification Sensor
  580
- Checking the Intake Air Pressure Sensor
  580
- Checking the Intake Air Temperature Sensor
  581
Troubleshooting
583
- Troubleshooting
  584
- General Information
  584
- Starting Failures
  584
- Incorrect Engine Idling Speed
  584
- Poor Medium-And-High-Speed Performance
  585
- Faulty Gear Shifting
  585
- Shift Pedal Does Not Move
  585
- Jumps out of Gear
  585
- Faulty Clutch
  585
- Overheating
  586
- Overcooling
  586
- Poor Braking Performance
  586
- Faulty Front Fork Legs
  586
- Unstable Handling
  586
- Faulty Lighting or Signaling System
  587

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