YAMAHA VMX17(Y) 2009 ASSEMBLY MANUALS

2009

VMX17(Y)

ASSEMBLY MANUAL

MANUEL DE MONTAGE

MONTAGEANLEITUNG

MANUALE DI ASSEMBLAGGIO

MANUAL DE MONTAJE

2S3-28107-50

FOREWORD

This Assembly Manual contains the infor­mation required for the correct assembly of
this Yamaha vehicle prior to delivery to the
customer. Since some external parts of the
vehicle have been removed at the Yamaha
factory for the convenience of packing, as­sembly by the Yamaha dealer is required.
It should be noted that the assembled vehi­cle should be thoroughly cleaned, inspect­ed, and adjusted prior to delivery to the
customer.

IMPORTANT

The service specifications given in this as­sembly manual are based on the model as
manufactured. Yamaha Motor Company,
Ltd. is continually striving to improve all of
its models. Modifications and significant
changes in specifications or procedures
will be forwarded to all authorized Yamaha
dealers and will appear in future editions of
this manual where applicable. The proce­dures below are described in the order that
the procedures are carried out correctly
and completely. Failure to do so can result
in poor performance and possible harm to
the vehicle and/or rider.

IMPORTANT MANUAL IN-

FORMATION

Particularly important information is distin­guished in this manual by the following no­tations.

This is the safety alert symbol. It is
used to alert you to potential personal
injury hazards. Obey all safety mes­sages that follow this symbol to avoid
possible injury or death.

SYMBOLS USED IN THE

ASSEMBLY MANUAL

(1) (2)

(3) (4)

(5) (6)

(7)

(8)

In order to simplify descriptions in this as­sembly manual, the following symbols are
used:

(1): Coat with lithium-soap-based grease.
(2): Tighten to 10 Nm. (10 Nm = 1.0 m•kg

= 7.2 ft•lb)
(3): Towards the front of the vehicle
(4): Clearance required
(5): Install so that the arrow mark faces

upward.
(6): Apply motor oil.
(7): Made of rubber or plastics
(8):

A: Ref. No. (indicating the order of

operations.)
B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held

V: Stored in plastic bag

C: Stored in carton box

S: Fixed inside the steel frame

and/or contained in the Sty­rofoam tray (upper or low­er)

*: Temporarily installed or se-

cured

E: Size or material of parts

d/D: Diameter of part

L: Length of part

e.g., 5 (0.20) = 5 mm (0.20 in)

A WARNING indicates a hazardous
situation which, if not avoided, could
result in death or serious injury.

A NOTICE indicates special precau­tions that must be taken to avoid dam­age to the vehicle or other property.

A TIP provides key information to make
procedures easier or clearer.

VMX17(Y) 2009

ASSEMBLY MANUAL

©2008 by Yamaha Motor Co., Ltd.

First Edition, September 2008

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.
is expressly prohibited.

Printed in the Netherlands

PREPARATION

To assemble the vehicle correctly, supplies
(e.g., oils, greases, and shop rags) and
sufficient working space are required.

Workshop

The workshop where the vehicle is assem­bled should be clean, spacious, and have a
level floor.

Self-protection

Protect your eyes with suitable safety
glasses or goggles when using com­pressed air, when grinding or when doing
any operation which may cause particles to
fly off. Protect hands and feet by wearing
safety gloves or shoes.

SYMBOLS USED ON

CRATE CARTON

(1) (2)

(3)

(5)

(4)

(6)

(1) Contents of the transport package are

fragile, therefore the package must be
handled with care.

(2) Indicates correct upright position of the

transport package.

(3) Transport package must be kept away

from rain.

(4) Insertion of the forklift arms from this

side can cause damage.

(5) Do not step anywhere on this carton

box.

(6) Up to 6 of the transport packages can

be piled up.

(7) Lift arm insertion position

If the forklift arms cannot be inserted
under the transport package in align­ment with the two yellow labels, adjust
the arms so that they are positioned
evenly in relation to these marks while
taking care not to damage the package
contents.

UNPACKING

1. Remove the frame cover (1).

To remove the frame cover, cut the plastic
bands around the cover using a cutter or
scissors.

1

2. Remove the handlebar holder bolts (2).

2

4

2

A. Right
B. Left

3. Remove the packing frames (3). (Lift
up and then move to the side.)

Remove the bolts while holding the frame.

3

3

3

4. Remove the front wheel axle holder
bolts (4).

Before starting the assembly, check for
damaged or missing parts. Check both the
parts contained in the carton boxes and on
the vehicle for damage, scratches, and oth­er defects.

3

-1-

PARTS LOCATION

312

1. Carton box 1

2. Carton box 2

3. Bubble wrap pack

4. Plastic bag

5. Front wheel

54

-2-

Carton box 1

1

3

5

18. Flange nuts (front fork guard) [d = 6
(0.24)]

19. Hexagon socket bolts (front fender

2

4

stay) [d = 6 (0.24), L = 16 (0.63)]

20. Hexagon socket bolts (front brake
hose clamp) [d = 6 (0.24), L = 10
(0.39)]

21. Hexagon socket bolt (front brake hose
holder) [d = 6 (0.24), L = 10 (0.39)]

22. Flange bolt (front wheel sensor lead
holder) [d = 6 (0.24), L = 12 (0.47)]

Carton box 2

1

6

7

1. Front wheel sensor housing

Bubble wrap pack

8910

11

12 13

14 15

16

17 18

19 20

21 22

1. Front fender

2. Front fork guards

3. Rear view mirrors

4. Owner's tool kit 2

5. Owner's manual

6. Plastic bag

7. Right front fender bracket

8. Front brake hose bracket

9. Left front fender bracket

10. Front brake hose holder

11. Plastic bag

12. Front fender stays

13. Front brake hose clamp

14. Key holder

15. Front wheel sensor lead holder

16. Plastic bag

17. Hexagon socket bolts (front fork guard)
[d = 6 (0.24), L = 16 (0.63)]

1

1. Collar (front wheel) [d = 22 (0.87)]

2. Hexagon socket bolt (front wheel sen­sor) [d = 6 (0.24), L = 14 (0.55)]

Plastic bag

1

1. Front wheel sensor

Front wheel

1

1. Front wheel

2

-3-

SETUP AND PREDELIVERY CHECKLIST

VMX17(Y) 2009

Check the following items again after setup and predelivery service have been completed.

A: INSTALLATION OF THE PARTS INCLUDED IN THE CRATE

□ FRONT WHEEL □ REAR VIEW MIRRORS
□ FRONT FENDER □ BATTERY

B: TIGHTENING TORQUE OF EACH PART

□ Front wheel axle bolt 81 Nm (8.1 m•kg, 59 ft•lb)
□ Front wheel axle pinch bolt 21 Nm (2.1 m•kg, 15 ft•lb)
□ Front brake caliper bolt 35 Nm (3.5 m•kg, 25 ft•lb)
□ Bolt (front wheel sensor lead holder) 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Front wheel sensor bolt 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Bolt (front fender stay) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Bolt (front fork guard) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Bolt (front brake hose holder) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Bolt (front brake hose clamp) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Bolt (battery cover) 3 Nm (0.3 m•kg, 2.2 ft•lb)
□ Bolt (top cover) 1.5 Nm (0.15 m•kg, 1.1 ft•lb)
□ Bolt (top cover) 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Bolt (multi-function display cover) 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Bolt (rider seat) 7 Nm (0.7 m•kg, 5.1 ft•lb)

C: ROUTING OF WIRE, CABLES, ETC.

□ Front wheel sensor lead □ Front brake hose
□ Positive battery lead □ Negative battery lead

D: ADJUSTMENTS

□ CHECKING AND CHARGING THE BATTERY □ BLEEDING THE HYDRAULIC BRAKE SYSTEM
□ MEASURING THE TIRE PRESSURE □ ADJUSTING THE CLUTCH LEVER
□ CHECKING THE ENGINE OIL LEVEL □ CHECKING THE CLUTCH FLUID LEVEL
□ CHECKING THE FINAL GEAR OIL LEVEL □ BLEEDING THE HYDRAULIC CLUTCH SYSTEM
□ CHECKING THE COOLANT LEVEL □ ADJUSTING THE FRONT FORK LEGS
□ ADJUSTING THE THROTTLE CABLE FREE PLAY □ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
□ ADJUSTING THE FRONT BRAKE □ ADJUSTING THE HEADLIGHT BEAM
□ ADJUSTING THE REAR BRAKE LIGHT SWITCH □ ADJUSTING THE DIGITAL CLOCK
□ CHECKING THE BRAKE FLUID LEVEL

E: FUNCTION AND PERFORMANCE

□ Check the function of the headlight, meter light and taillight □ Check the function of the indicator on the speedometer
□ Check the function of the brake light □ Check the feel of the brakes
□ Check the function of the turn signal lights and indicator lights □ Check engine for irregular noise (Yes/No)
□ Check the tone quality of the horn □ Check for exhaust leak (Yes/No)

F: ACCESSORIES, ETC. FOR DELIVERY

□ Owner's manual □ Key holder
□ Owner's tool kit

-4-

SETUP PROCEDURES

Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

12 43

-5-

1. FRONT WHEEL

J

8

7

35

J

8

8

35

8

G

H

81

5

7

B

21

11

D

1C

1V

4

K

9

10

M

12

d = 14 (0.55), L =
23 (0.91)
d = 8 (0.31), L = 45
(1.77)

d = 10 (0.39), L =
71 (2.8)

d = 6 (0.24), L = 12
(0.47)

d = 6 (0.24), L = 14
(0.55)

L

7

7

I

21

6

C

6

6

I

2

1

F

F

1 Front wheel 1 S
2 Collar 1 V d = 22 (0.87)

Front wheel sensor hous-

3

ing

4 Front wheel axle 1 *

5 Front wheel axle bolt 1 *

6 Front wheel axle pinch bolt 4 *

7 Front brake caliper 2 *

8 Flange bolt 4 *

Front wheel sensor lead

9

holder

10 Flange bolt 1 V

11 Front wheel sensor 1 V

12 Hexagon socket bolt 1 V

A: Clean the brake discs.
B: Clean the front wheel axle.
C: Clean the collar.
D: Clean the front wheel sensor housing.
E:

Take care not to get grease on the brake discs or inner sur­face of the brake pads. If you do so, clean using a rag damp­ened with a solvent. Foreign material on braking surface
may cause impaired braking action.

A,E

3

Do not depress the brake lever when the calipers are off the
brake discs.

G: Make sure that the slot in the front wheel sensor housing is

aligned with the stopper on the front fork outer tube.

H: Apply the light coat of grease to the contact surface of the

bolt. Tighten the front wheel axle bolt to specification.

Front wheel axle bolt

81 Nm (8.1 m•kg, 59 ft•lb)

Before tightening the pinch bolt, stroke the front forks sev­eral times to make sure of proper fork operation.

I: Tighten the axle pinch bolts to specification.

Front wheel axle pinch bolt

21 Nm (2.1 m•kg, 15 ft•lb)

Refer to "TIGHTENING TORQUE".

J: Tighten the front brake caliper bolts to specification.

Front brake caliper bolt

35 Nm (3.5 m•kg, 25 ft•lb)

K: Make sure that the "UP" mark on the holder is pointed up-

ward as indicated by the arrow, with the mark facing inward.

L: Tighten the bolt to specification.

Bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)

M: Tighten the front wheel sensor bolt to specification.

Front wheel sensor bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)

To route the front wheel sensor lead, refer to "CABLE ROUT­ING".

2. FRONT FENDER

A,B

10

8

C

10

7

8

C

8

F

G

10

9

13

13

12

3

4

6

5

6

8

10

6

A,B

5

6

10

10

C

7

8

10

F: Lift the front wheel and install the front wheel axle. Be sure

the arrow on the tire is pointed in the rotating direction.

• Keep magnets (including magnetic pick-up tools, magnet­ic screwdrivers, etc.) away from the wheel sensor rotor.

• Do not drop the wheel sensor rotor or subject it to shocks.

• If any solvent gets on the wheel sensor rotor, wipe it off im­mediately.

-6-

9

11

E

10

2

1

D

8

C

10

1 Left front fender bracket 1 V
2 Right front fender bracket 1 V
3 Front fender 1 C
4 Front brake hose bracket 1 V
5 Front fender stay 2 V

6 Hexagon socket bolt 4 V

7 Front fork guard 2 C

8 Hexagon socket bolt 6 V

9 Flange nut 2 V d = 6 (0.24)

10 Front brake hose holder 1 V

11 Hexagon socket bolt 1 V

12 Front brake hose clamp 1 V

13 Hexagon socket bolt 2 V

A: Apply locking agent (LOCTITE®).
B: Tighten the bolts to specification.

Bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)

Be careful not to scratch the front fender with the front fork
outer tube.

d = 6 (0.24), L = 16
(0.63)

d = 6 (0.24), L = 16
(0.63)

d = 6 (0.24), L = 10
(0.39)

d = 6 (0.24), L = 10
(0.39)

4. BATTERY

G

7

12

13

11

F

7

F

7

9

8

E

1.5

10

5

6

F

C

7

B

3

6

D

11

F

7

9

7
E

1.5

B

3

3

A

8

4

4

2

1

C: Tighten the bolts to specification.

Bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)

D: Fasten the front brake hose and front wheel sensor lead with

the front brake hose holder.

E: Tighten the bolt to specification.

Bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)

F: Fasten the front brake hose with the front brake hose clamp.
G: Tighten the bolts to specification.

Bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)

Proper cable routing is essential to assure safe vehicle op­eration.
Refer to "CABLE ROUTING".

3. REAR VIEW MIRRORS

1

1 Left rear view mirror 1 C
2 Right rear view mirror 1 C

2

2 *

15, H

d = 6 (0.24), L = 10
(0.39)

d = 6 (0.24), L = 20
(0.79)
d = 6 (0.24), L = 18
(0.71)
d = 6 (0.24), L = 10
(0.39)
d = 6 (0.24), L = 12
(0.47)

d = 6 (0.24), L = 10
(0.39)

d = 6 (0.24), L = 30
(1.18)

14

1 Battery seat 1 *
2 Battery 1 *
3 Rubber damper 1 *
4Nut 2 * d = 6 (0.24)
5 Battery cover 1 *

6Bolt 2 *

7 Top cover 1 *

8 Hexagon socket bolt 2 *

9 Hexagon socket bolt 2 *

10 Hexagon socket bolt 2 *

Hexagon socket bolt with

11

plain washer

12 Multi-function display cover 1 *

13 Hexagon socket bolt 1 *

14 Rider seat 1 *

15 Hexagon socket bolt 2 *

A: Installing the battery.

Refer to "ADJUSTMENTS AND PREDELIVERY SERVICE".

-7-

B: Tighten the bolts to specification.

Bolt

3 Nm (0.3 m•kg, 2.2 ft•lb)

C: First, connect the positive lead (red lead) to the positive ter-

minal.

D: Second, connect the negative lead (black lead) to the nega-

tive terminal.

Refer to "CABLE ROUTING".

E: Tighten the bolts to specification.

Bolt

1.5 Nm (0.15 m•kg, 1.1 ft•lb)

F: Tighten the bolts to specification.

Bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)

G: Tighten the bolt to specification.

Bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)

H: Tighten the bolts to specification.

Bolt

7 Nm (0.7 m•kg, 5.1 ft•lb)

-8-

CABLE ROUTING

3

1

2

Proper cable and lead routing are essential to insure safe ve­hicle operation.

1. Front wheel sensor lead

2. Front brake hose

3. Negative battery lead

4. Positive battery lead

4

-9-

ADJUSTMENTS AND PREDELIVERY SERVICE

Perform the predelivery service in the order indicated by the letters. Always follow the order as shown.

B P AO

M

J

I

F

O

I

G

B DJ KL Q

NN

J

-10-

CO H

E

A. CHECKING AND CHARGING

THE BATTERY

The battery used in this vehicle is a VRLA
(Valve Regulated Lead Acid) battery, it has
been pre-filled with electrolyte at the facto­ry so there is no need to add fluid at any
time.

1. Check:

Using a digital volt meter, the state of a
discharged VRLA (Valve Regulated
Lead Acid) battery can be checked by
measuring open-circuit voltage (the
voltage measured with the positive and
negative terminals being disconnect­ed).

Open-circuit voltage

12.8 V or higher

Charging time

Charging is not necessary

• Do not attempt boost charging under
any circumstances.

• Battery electrolyte is poisonous and
dangerous, causing severe burns,
etc. It contains sulfuric acid. Avoid
contact with skin, eyes or clothing.
Antidote: External -Flush with water.
Internal-Drink large quantities of wa­ter or milk. Follow with milk of magne­sia, beaten egg, or vegetable oil. Call
physician immediately.
Eyes: Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc.,
away. Ventilate when charging or us­ing in enclosed space. Always shield
eyes when working near batteries.
KEEP OUT OF THE REACH OF CHIL­DREN.

• If the voltage is lower than 12.8 V the
battery must be charged. If this is not
done, the life of the battery will be
shortened drastically. Refer to the
service manual for battery charging
instructions.

• Never remove the strip of caps, nor
add any water or electrolyte.

B. MEASURING THE TIRE PRES-

SURE

1. Measure:

• tire pressure

Out of specification → Adjust.

• The tire pressure and the suspension
must be adjusted according to the to­tal weight (including cargo, rider, pas­senger, and accessories) and the
anticipated riding speed.

• Operation of an overloaded vehicle
could cause tire damage, an accident,
or an injury.
NEVER OVERLOAD THE VEHICLE.

Basic weight:

With oil and full fuel tank

310 kg (683 lb)

Maximum load*

190 kg (419 lb)

Cold tire pressure

Up to 90 kg (198 lb) load*

Front

250 kPa (2.50 kgf/cm

Rear

290 kPa (2.90 kgf/cm

90kg (198 lb)–Maximum load*

Front

250 kPa (2.50 kgf/cm

Rear

290 kPa (2.90 kgf/cm

High speed riding

Front

290 kPa (2.90 kgf/cm

Rear

290 kPa (2.90 kgf/cm
* Load is the total weight of cargo, rider,
passenger and accessories.

2

, 36 psi)

2

, 42 psi)

2

, 36 psi)

2

, 42 psi)

2

, 42 psi)

2

, 42 psi)

C. CHECKING THE ENGINE OIL

LEVEL

1. Stand the vehicle on a level surface.

• Place the vehicle on a suitable stand.

• Make sure that the vehicle is upright.

2. Let the engine idle for a few minutes,
and then turn it off.

3. Check:

• engine oil level
The engine oil level should be between
the minimum level mark (a) and maxi­mum level mark (b).
Below the minimum level mark → Add
the recommended engine oil to the
proper level.

Before checking the engine oil level, wait a
few minutes until the oil has settled.

b
a

Recommended engine oil type

SAE 10W-30, SAE 10W-40, SAE
15W-40, SAE 20W-40 or SAE 20W-50

Recommended engine oil grade

API service SG type or higher, JASO
standard MA

Quantity

Without oil filter cartridge replacement

4.30 L (3.78 Imp qt, 4.55 US qt)

• Engine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. There­fore, do not add any chemical addi­tives or use engine oils with a grade of
CD (c) or higher and do not use oils la­beled "ENERGY CONSERVING II" (d).

• Do not allow foreign materials to enter
the crankcase.

c

4

d

4. Start the engine, warm it up for several

minutes, and then turn it off.

5. Check the engine oil level again.

Before checking the engine oil level, wait a
few minutes until the oil has settled.

D. CHECKING THE FINAL GEAR

OIL LEVEL

1. Stand the vehicle on a level surface.

• Place the vehicle on a suitable stand.

• Make sure that the vehicle is upright.

2. Check:

• final gear oil level

a. Loosen the final gear oil check bolt (1)

until oil flows out.

• The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.

1

-11-

b. If no oil flows out, add the recommend-

ed final gear oil until it flows out.

Recommended final gear oil type

Shaft drive gear oil (Part No.: 9079E­SH001-00)

Oil quantity

0.30 L (0.26 Imp qt, 0.32 US qt)

c. Tighten the final gear oil check bolt to

specification.

Final gear oil check bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)

E. CHECKING THE COOLANT

LEVEL

1. Stand the vehicle on a level surface.

• Place the vehicle on a suitable stand.

• Make sure that the vehicle is upright.

2. Check:

• coolant level

The coolant level should be between
the minimum level mark (a) and maxi­mum level mark (b).
Below the minimum level mark → Add
the recommended coolant to the prop­er level.

• Adding water instead of coolant low­ers the antifreeze content of the cool­ant. If water is used instead of
coolant, check and correct the anti­freeze concentration of the coolant.

• Use only distilled water. Soft water
may be used if distilled water is not
available.

b
a

3. Start the engine, warm it up for several

minutes, and then turn it off.

4. Check:

• coolant level

Before checking the coolant level, wait a
few minutes until it settles.

F. ADJUSTING THE THROTTLE

CABLE FREE PLAY

1. Measure:

• throttle cable free play (a)

Out of specification → Adjust.

Throttle cable free play (at the flange of
the throttle grip)

3–5 mm (0.12–0.20 in)

a

2. Adjust:
a. Slide back the rubber cover (1).
b. Loosen the locknut (2).
c. Turn the adjusting nut (3) in direction

(a) or (b) until the specified throttle ca­ble free play is obtained.

Direction (a)

Throttle cable free play is increased.

Direction (b)

Throttle cable free play is decreased.

d. Tighten the locknut.
e. Slide the rubber cover to its original po-

sition.

After adjusting the throttle cable free
play, turn the handlebar to the right and
to the left to ensure that this does not
cause the engine idling speed to
change.

a

1

2

3

b

G. ADJUSTING THE FRONT

BRAKE

1. Adjust:

• brake lever position
(distance (a) from the throttle grip to
the brake lever)

a. While pushing the brake lever forward,

turn the adjusting knob (1) until the
brake lever is in the desired position.

Be sure to align the setting on the adjusting
knob with the arrow mark (2) on the brake
lever holder.

Direction (b)

Distance (a) is the largest.

Direction (c)

Distance (a) is the smallest.

After adjusting the brake lever position,
make sure that there is no brake drag.

A soft or spongy feeling in the brake le­ver can indicate the presence of air in
the brake system. Before the vehicle is
operated, the air must be removed by
bleeding the brake system. Air in the
brake system will considerably reduce
braking performance and could result in
loss of control and possibly an acci­dent. Therefore, check the brake system
and bleed if necessary.

1

a

b

2

c

H. ADJUSTING THE REAR BRAKE

LIGHT SWITCH

• The rear brake light switch is operated by
the movement of the brake pedal.

• The rear brake light switch is properly ad­justed when the brake light comes on just
before the braking effect starts.

1. Check:

• rear brake light operation timing

Incorrect → Adjust.

2. Adjust:

• rear brake light operation timing

a. Hold the main body (1) of the rear

brake light switch so that it does not ro­tate and turn the adjusting nut (2) in di­rection (a) or (b) until the rear brake
light comes on at the proper time.

Direction (a)

Brake light comes on sooner.

Direction (b)

Brake light comes on later.

2

a

1

b

I. CHECKING THE BRAKE FLUID

LEVEL

1. Stand the vehicle on a level surface.

• Place the vehicle on a suitable stand.

• Make sure that the vehicle is upright.

• The rear brake fluid reservoir is located
under the passenger seat.

-12-

2. Check:

• brake fluid level
Below the minimum level mark (a) →
Add the recommended brake fluid to
the proper level.

Recommended brake fluid

DOT 4

• Use only designated brake fluid. Oth­er brake fluids may cause the rubber
seals to deteriorate, causing leakage
and poor brake performance.

• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.

• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the brake fluid and could
cause vapor lock.

Brake fluid may damage painted surfac­es and plastic parts. Therefore, always
clean up any split brake fluid immedi­ately.

In order to ensure a correct reading of the
brake fluid level, make sure that the top of
the reservoir is level.

1. Remove:

• passenger seat

• Be careful not to spill any brake fluid or
allow the brake master cylinder reservoir
or brake fluid reservoir to overflow.

• When bleeding the hydraulic brake sys­tem, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could al­low air to enter the hydraulic brake sys­tem, considerably lengthening the
bleeding procedure.

• If bleeding is difficult, it may be neces­sary to let the brake fluid settle for a few
hours. Repeat the bleeding procedure
when the tiny bubbles in the hose have
disappeared.

2. Bleed:

• hydraulic brake system

a. Add the recommended brake fluid to

the proper level.

b. Install the brake master cylinder reser-

voir diaphragm and brake reservoir di­aphragm.

c. Connect a clear plastic hose (1) tightly

to the bleed screw (2).

2

1

Bleed screw

Front

5 Nm (0.5 m•kg, 3.6 ft•lb)

Rear

6 Nm (0.6 m•kg, 4.3 ft•lb)

k. Fill the reservoir to the proper level.

Refer to "CHECKING THE BRAKE
FLUID LEVEL".

After bleeding the hydraulic brake sys­tem, check the brake operation.

3. Install:

• passenger seat

K. ADJUSTING THE CLUTCH LE-

VER

1. Adjust:

• clutch lever position
(distance (a) from the handlebar grip to
the clutch lever)

a. While pushing the clutch lever forward,

turn the adjusting dial (1) until the
clutch lever is in the desired position.

Be sure to align the setting on the adjusting
dial with the arrow mark (2) on the clutch le­ver holder.

Position #1

Distance (a) is the largest.

Position #4

Distance (a) is the smallest.

a

a

A. Front brake
B. Rear brake

J. BLEEDING THE HYDRAULIC

BRAKE SYSTEM

Bleed the hydraulic brake system when­ever:

• the system was disassembled,

• a brake hose was loosened or re­moved,

• the brake fluid level is very low,

• brake operation is faulty.

2

1

A. Front brake
B. Rear brake

d. Place the other end of the hose into a

container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully

depress the brake pedal and hold it in

position.
g. Loosen the bleed screw. This will re-

lease the tension and cause the brake

lever to contact the throttle grip or the

brake pedal to fully extend.
h. Tighten the bleed screw and then re-

lease the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the

brake fluid in the plastic hose.
j. Tighten the bleed screw to specifica-

tion.

1

a

1

2

L. CHECKING THE CLUTCH FLUID

LEVEL

1. Stand the vehicle on a level surface.

• Place the vehicle on a suitable stand.

• Make sure that the vehicle is upright.

2. Remove:

• clutch master cylinder reservoir cap

• clutch master cylinder reservoir dia­phragm holder

• clutch master cylinder reservoir dia­phragm

3. Check:

• clutch fluid level
Below the minimum level mark (a) →
Add the recommended clutch fluid to
the proper level.

Recommended clutch fluid

Brake fluid DOT 4

-13-

• Use only the designated clutch fluid.
Other clutch fluids may cause the rub­ber seals to deteriorate, causing leak­age and poor clutch performance.

• Refill with the same type of clutch flu­id that is already in the system. Mixing
clutch fluids may result in a harmful
chemical reaction, leading to poor
clutch performance.

• When refilling, be careful that water
does not enter the reservoir. Water
will significantly lower the boiling
point of the clutch fluid and could
cause vapor lock.

Clutch fluid may damage painted sur­faces or plastic parts. Therefore, always
clean up any spilt clutch fluid immedi­ately.

In order to ensure a correct reading of the
clutch fluid level, make sure that the top of
the reservoir is level.

a

UPPER
LOWER

4. Install:

• clutch master cylinder reservoir dia-

phragm

• clutch master cylinder reservoir dia-

phragm holder

• clutch master cylinder reservoir cap

M. BLEEDING THE HYDRAULIC

CLUTCH SYSTEM

Bleed the hydraulic clutch system
whenever:

• the system was disassembled,

• a clutch hose was loosened or re­moved,

• the clutch fluid level is very low,

• clutch operation is faulty.

1. Remove:

• clutch release cylinder cover (1)

• Be careful not to spill any clutch fluid or
allow the clutch fluid reservoir to over­flow.

• When bleeding the hydraulic clutch sys­tem, make sure that there is always
enough clutch fluid before applying the
clutch lever. Ignoring this precaution
could allow air to enter the hydraulic
clutch system, considerably lengthening
the bleeding procedure.

• If bleeding is difficult, it may be neces­sary to let the clutch fluid settle for a few
hours. Repeat the bleeding procedure
when the tiny bubbles in the hose have
disappeared.

1

2. Bleed:

• hydraulic clutch system

a. Add the recommended clutch fluid to

the proper level.

b. Install the clutch fluid reservoir dia-

phragm.

c. Connect a clear plastic hose (1) tightly

to the bleed screw (2).

1

2

d. Place the other end of the hose into a

container.

e. Slowly squeeze the clutch lever sever-

al times and release it.

f. Fully squeeze the clutch lever and do

not release it.

g. Loosen the bleed screw. This will re-

lease the tension and cause the clutch
lever to contact the handlebar grip.

h. Tighten the bleed screw and then re-

lease the clutch lever.

i. Repeat steps (e) to (h) until all of the air

bubbles have disappeared from the
clutch fluid in the plastic hose.

j. Tighten the bleed screw to specifica-

tion.

Bleed screw

5 Nm (0.5 m•kg, 3.6 ft•lb)

k. Add the recommended clutch fluid to

the proper level.
Refer to "CHECKING THE CLUTCH
FLUID LEVEL".

After bleeding the hydraulic clutch sys­tem, check the clutch operation.

3. Install:

• clutch release cylinder cover

Clutch release cylinder cover bolt

10 Nm (1.0 m•kg, 7.2 ft•lb)

N. ADJUSTING THE FRONT FORK

LEGS

The following procedure applies to both of
the front fork legs.

• Always adjust both front fork legs
evenly. Uneven adjustment can result
in poor handling and loss of stability.

• Securely support the vehicle so that
there is no danger of it falling over.

Spring preload

• Grooves are provided to indicate the
adjustment position.

• Never go beyond the maximum or
minimum adjustment positions.

1. Adjust:

• spring preload

a. Turn the adjusting bolt (1) in direction

(a) or (b).

Direction (a)

Spring preload is increased (suspen­sion is harder).

Direction (b)

Spring preload is decreased (suspen­sion is softer).

a

Adjusting positions

Standard: 4
Minimum: 5
Maximum: 1

Rebound damping

Never go beyond the maximum or mini­mum adjustment positions.

1. Adjust:

• rebound damping

a. Turn the adjusting screw (1) in direc-

tion (a) or (b).

1

b

1

2

3

4

5

-14-

Direction (a)

Rebound damping is increased (sus­pension is harder).

Direction (b)

Rebound damping is decreased (sus­pension is softer).

Adjusting positions

Standard: 12 clicks out*
Minimum: 17 clicks out*
Maximum: 1 click out*

*: from the fully turned-in position

a

1

b

Compression damping

Never go beyond the maximum or mini­mum adjustment positions.

1. Adjust:

• compression damping

a. Turn the adjusting screw (1) in direc-

tion (a) or (b).

Direction (a)

Compression damping is increased
(suspension is harder).

Direction (b)

Compression damping is decreased
(suspension is softer).

Adjusting positions

Standard: 12 clicks out*
Minimum: 20 clicks out*
Maximum: 1 click out*

*: from the fully turned-in position

a

1

b

O. ADJUSTING THE REAR SHOCK

ABSORBER ASSEMBLY

Securely support the vehicle so that
there is no danger of it falling over.

Spring preload

1. Adjust:

• spring preload

a. Turn the adjusting knob (1) in direction

(a) or (b).

Direction (a)

Spring preload is increased (suspen­sion is harder).

Direction (b)

Spring preload is decreased (suspen­sion is softer).

a

1

b

Adjusting positions

Standard: 6
Minimum: 11
Maximum: 1

11

10

9

8

7

6

5

4

3

2

1

Rebound damping

Never go beyond the maximum or mini­mum adjustment positions.

1. Adjust:

• rebound damping

a. Turn the adjusting screw (1) in direc-

tion (a) or (b).

Direction (a)

Rebound damping is increased (sus­pension is harder).

Direction (b)

Rebound damping is decreased (sus­pension is softer).

Adjusting positions

Standard: 12 clicks out*
Minimum: 20 clicks out*
Maximum: 3 clicks out*

*: from the fully turned-in position

a

Compression damping

Never go beyond the maximum or mini­mum adjustment positions.

1. Adjust:

• compression damping

a. Turn the adjusting screw (1) in direc-

tion (a) or (b).

Direction (a)

Compression damping is increased
(suspension is harder).

Direction (b)

Compression damping is decreased
(suspension is softer).

Adjusting positions

Standard: 10 clicks out*
Minimum: 12 clicks out*
Maximum: 1 click out*

*: from the fully turned-in position

b

1

a

P. ADJUSTING THE HEADLIGHT

BEAM

1. Adjust:

• headlight beam (vertically)

a. Turn the adjusting screw (1) in direc-

tion (a) or (b).

Direction (a)

Headlight beam is raised.

Direction (b)

Headlight beam is lowered.

bb

aa

1

2. Adjust:

• headlight beam (horizontally)

a. Turn the adjusting screw (1) in direc-

tion (a) or (b).

Direction (a)

Headlight beam moves to the right.

Direction (b)

Headlight beam moves to the left.

• Marks are provided to indicate the ad­justment position.

• Never go beyond the maximum or
minimum adjustment positions.

1

b

a

b

1

-15-

Q. ADJUSTING THE DIGITAL

CLOCK

1. Turn the key to "ON".

2. Push and hold the "SELECT" button

(1) and "RESET" button (2) for at least
three seconds to enter the Select
mode.

• The transmission must be in neutral to
change settings in this mode.

• Shifting the transmission in gear will con­firm all settings made in this mode, and
the display will change to the Normal
mode.

12

3. Adjust:

• digital clock (1)

1

a. Push the "SELECT" button to highlight

"Display", then push the "RESET" but­ton.

b. Push the "RESET" button and the hour

digits start flashing.

c. Push the "SELECT" button to incre-

ment the hours.

d. Push the "RESET" button, and the

minute digits starts flashing.

e. Push the "SELECT" button to incre-

ment the minutes.

f. Push the "RESET" button to start the

clock.

g. Push the "RESET" button again to re-

turn to the previous menu or push the
"SELECT" button to scroll to "All reset".

-16-

APPENDICES

SERVICE DATA
Engine idling speed:

950–1,050 r/min

Spark plug:

Type (manufacturer)
CR9EIA (NGK) or IU27D (DENSO)
Gap

0.8–0.9 mm (0.031–0.035 in)

Fuel:

Recommended fuel
Premium unleaded gasoline only
Fuel tank capacity
Total:

15.0 L (3.30 Imp gal, 3.96 US gal)

Valve clearance (cold):

IN

0.10–0.17 mm (0.0039–0.0067 in)
EX

0.22–0.29 mm (0.0087–0.0114 in)

Maximum load*:

190 kg (419 lb)

Tire pressure:

Up to 90 kg (198 lb) load*
Front
250 kPa (2.50 kgf/cm
Rear
290 kPa (2.90 kgf/cm
90 kg (198 lb) load–Maximum load*
Front
250 kPa (2.50 kgf/cm
Rear
290 kPa (2.90 kgf/cm
High-speed riding
Front
290 kPa (2.90 kgf/cm
Rear

290 kPa (2.90 kgf/cm
* Load is the total weight of cargo, rider,
passenger, and accessories.

STANDARD EQUIPMENT

Owner's manual × 1

Owner's tool kit × 2

Key holder × 1

OWNER'S TOOL KIT

Owner's tool bag 1 × 1

Screwdriver bit (Phillips) × 1
Screwdriver bit (Phillips-slotted) × 1
Screwdriver grip × 1
Pliers × 1
Wrench (8-10) × 1
Wrench (10-12) × 1
Wrench (12-14) × 1
Wrench (14-17) × 1
Hexagon wrench (4) × 1
Hexagon wrench (5) × 1
Hexagon wrench (6) × 1

Owner's tool bag 2 × 1

Spark plug wrench × 1

2

, 36 psi)

2

, 42 psi)

2

, 36 psi)

2

, 42 psi)

2

, 42 psi)

2

, 42 psi)

-17-

TIGHTENING TORQUE

Item Thread size

Engine:
Spark plug M10 13 1.3 9.4
Engine oil drain bolt M14 43 4.3 31
Chassis:
Engine bracket bolt (top) M12 60 6.0 43
Engine mounting bolt (front side) M12 60 6.0 43
Engine mounting nut (front side) M12 60 6.0 43
Engine mounting bolt (left and right) M10 60 6.0 43
Engine mounting bolt (rear upper side) M12 60 6.0 43
Engine mounting nut (rear lower side) M12 60 6.0 43
Rear frame bolt M10 41 4.1 30
Front brake hose joint bolt M6 7 0.7 5.1
Pivot shaft (left) M28 100 10 72
Pivot shaft (right) M28 7 0.7 5.1
Pivot shaft nut M28 100 10 72
Connecting arm and swingarm bolt M16 8 0.8 5.8
Connecting arm and swingarm nut (left) M16 48 4.8 35
Connecting arm and swingarm nut (right) M10 48 4.8 35
Connecting arm and relay arm bolt M18 8 0.8 5.8
Connecting arm and relay arm nut (left) M18 56 5.6 40
Connecting arm and relay arm nut (right) M12 70 7.0 50
Frame bracket and relay arm nut (left) M12 70 7.0 50
Frame bracket and relay arm bolt M18 8 0.8 5.8
Frame bracket and relay arm nut (right) M18 56 5.6 40
Rear shock absorber assembly lower bolt M14 45 4.5 32
Damper and swingarm bolt M8 16 1.6 11
Torque stopper bolt M22 115 11.5 85
Rear brake hose clamp bolt M6 7 0.7 5.1
Rear shock absorber assembly upper nut M10 45 4.5 32
Upper bracket pinch bolt M8 26 2.6 19
Steering stem nut M22 115 11.5 85
Handlebar holder bolt M8 28 2.8 20
Lower ring nut M28 See TIP.
Lower handlebar holder nut M10 32 3.2 23
Front brake master cylinder holder bolt M6 14 1.4 10
Lower bracket pinch bolt M8 23 2.3 17
Front brake hose union bolt (front brake master cylinder side) M10 30 3.0 22
Brake hose and front fender bolt M6 10 1.0 7.2
Front brake hose joint holder bolt M6 7 0.7 5.1
Brake hose holder and upper radiator bracket bolt M6 7 0.7 5.1
Handlebar switch screw M5 4 0.4 2.9
Throttle cable adjusting nut M6 4 0.4 2.9
Lean angle sensor bolt M4 2 0.2 1.4
Brake pipe flare nut M10 21 2.1 15
Brake pipe flare nut (hydraulic unit) M10 16 1.6 11
Fuel pump nut M6 10 1.0 7.2
Filler neck nut M6 10 1.0 7.2
Front wheel axle bolt M14 81 8.1 59
Front wheel axle pinch bolt M8 See TIP.
Front brake caliper bolt M10 35 3.5 25
Brake hose union bolt M10 30 3.0 22
Front wheel sensor bolt M6 7 0.7 5.1
Rear wheel sensor bolt M6 7 0.7 5.1
Rear wheel axle M24 98 9.8 71
Rear wheel axle pinch bolt M8 16 1.6 11
Front brake disc bolt M6 18 1.8 13
Rear brake disc bolt M8 23 2.3 17
Front wheel sensor rotor bolt M5 8 0.8 5.8
Rear wheel sensor rotor bolt M5 8 0.8 5.8
Rear brake master cylinder bolt M8 28 2.8 20

Tightening torque

Nm m•kg ft•lb

-18-

Lower ring nut

1. First, tighten the lower ring nut to approximately 52 Nm (5.2 m•kg, 37 ft•lb) with a torque wrench, then loosen the lower ring nut completely.

2. Retighten the lower ring nut to 18 Nm (1.8 m•kg, 13 ft•lb) with a torque wrench.

Front wheel axle pinch bolt

1. Insert the front wheel axle from the left side and tighten it with the flange bolt from the right side to 81 Nm (8.1 m•kg, 59 ft•lb) without

performing temporary tightening.

2. In the order pinch bolt (3) → pinch bolt (4) → pinch bolt (3), tighten each bolt to 21 Nm (2.1 m•kg, 15 ft•lb) without performing temporary

tightening.

3. Check that the left end of the front axle is flush with the front fork. If necessary, manually push the front axle or lightly tap it with a soft

hammer until its end is flush with the front fork. However, if the surface of the front axle end is not parallel to the surface of the front fork,
align a point on the outer edge of the axle with the fork, making sure that the axle does not protrude past the fork.

4. In the order pinch bolt (2) → pinch bolt (1) → pinch bolt (2), tighten each bolt to 21 Nm (2.1 m•kg, 15 ft•lb) without performing temporary

tightening.

4

3

1

2

-19-

AVANT-PROPOS

Ce Manuel de montage contient les in­structions nécessaires au montage en
bonne et due forme de ce véhicule Yama­ha avant sa livraison au client. Certaines
pièces du véhicule ayant été déposées à
l’usine Yamaha pour plus de commodité
lors du transport, celles-ci doivent être re­montées par le concessionnaire Yamaha.
Prendre note qu’après son assemblage, il
sera nécessaire de nettoyer, contrôler et
régler minutieusement le véhicule avant sa
livraison au client.

IMPORTANT

Les données techniques présentées dans
ce manuel sont celles déterminées au
début de la production de ce modèle. La
Yamaha Motor Company, Ltd. s’efforce en
permanence d’améliorer tous ses produits.
Les modifications et les changements sig­nificatifs dans les caractéristiques ou les
procédés seront notifiés à tous les conces­sionnaires Yamaha et paraîtront, à l’endroit
approprié, dans les éditions futures de ce
manuel. Il convient de suivre les procédés
expliqués dans ce manuel dans l’ordre
donné afin d’assurer un remontage correct
et complet du véhicule. Le non-respect de
cette consigne risque de compromettre les
performances du véhicule, mais aussi
d’être la cause de dommages matériels et
corporels.

INFORMATIONS IMPOR-

TANTES CONCERNANT

LE MANUEL

Les informations particulièrement impor­tantes sont repérées par les notations sui­vantes:

SYMBOLES UTILISÉS

DANS LE MANUEL DE

MONTAGE

(1) (2)

(3) (4)

(5) (6)

(7)

(8)

Les symboles suivants ont été adoptés en
vue de simplifier les explications:

(1): Enduire de graisse à base de savon

aulithium.

(2): Serrer à 10 Nm. (10 Nm = 1.0 m•kg =

7.2 ft•lb)
(3): Avant du véhicule
(4): Jeu requis
(5): Monter de sorte que la flèche soit di-

rigée vers le haut.
(6): Enduire d'huile moteur.
(7): Pièce en caoutchouc ou en plastique
(8):

A: N° d'étape (indiquant l'ordre de

travail)
B: Nom de la pièce
C: Quantité de pièces par véhicule
D: Endroit où sont conservées les

pièces

V: Dans sac en plastique

C: Dans boîte en carton

S: Attaché côté intérieur du

cadre en acier et/ou situé
dans les bacs en mousse
supérieur ou inférieur.

*: Monté ou attaché de façon

provisoire

E: Taille ou matériau des pièces

d/D: Diamètre de pièce

L: Longueur de pièce

ex.: 5 (0.20) = 5 mm (0.20 in)

Il s'agit du symbole avertissant d'un
danger. Il avertit de dangers de dom­mages personnels potentiels. Observ­er scrupuleusement les messages
relatifs à la sécurité figurant à la suite
de ce symbole afin d'éviter les dan­gers de blessures ou de mort.

Un AVERTISSEMENT signale un dan­ger qui, s'il n'est pas évité, peut provo­quer la mort ou des blessures graves.

Un ATTENTION indique les précau­tions particulières à prendre pour évit­er d'endommager le véhicule ou
d'autres biens.

Un N.B. fournit les renseignements
nécessaires à la clarification et la simpli­fication des divers travaux.

VMX17(Y) 2009

MANUEL DE MONTAGE

©2008 Yamaha Motor Co., Ltd.

Première édition, septembre 2008

Tous droits réservés

Toute reproduction ou utilisation

sans la permission écrite
de Yamaha Motor Co., Ltd.
est formellement interdite.

Imprimé aux Pays-Bas

PRÉPARATION

Certaines fournitures (ex.: huiles, graisses
et essuyeurs) et un espace de travail suff­isamment spacieux sont indispensables
pour monter correctement le véhicule.

Atelier

Assembler le véhicule à un endroit propre
et spacieux et dont le sol est plane.

Sécurité

Se protéger les yeux avec des lunettes de
protection lors de l’utilisation d’air com­primé, lors de meulages ou lors de tout tra­vail entraînant la projection de particules.
Se protéger les mains et les pieds à l’aide
de gants et de chaussures de protection.

SYMBOLES FIGURANT

SUR LE CARTON D’EM-

BALLAGE

(1) (2)

(3)

(5)

(4)

(6)

(1) Le contenu de cet emballage est frag-

ile ; par conséquent, il convient de ma­nipuler ce carton avec soin.

(2) Indique la position droite correcte de

l'emballage.

(3) Conserver l'emballage à l'abri de la

pluie.

(4) L'introduction des fourches de chariot

élévateur par ce côté pourrait causer
des dommages.

(5) Ne pas marcher ou reposer le pied sur

une partie quelconque de la boîte en
carton.

(6) Un maximum de 6 de ces emballages

de transport peuvent être empilés.

(7) Position d’insertion de fourche

S’il est impossible d’aligner les fourch­es du chariot élévateur sur les éti­quettes jaunes figurant sur la caisse, il
faut veiller à les placer de sorte à ce
que la distance entre celles-ci et les
étiquettes soit égale de part et d’autre
et de sorte à ne pas abîmer le contenu.

DÉBALLAGE

1. Retirer le carton du cadre (1).

Couper les bandes en plastique entourant
le carton à l’aide de ciseaux ou d’un cou­teau.

1

2. Déposer les vis (2) de support du gui­don.

2

4

2

A. Droite
B. Gauche

3. Déposer les lattes (3) du cadre. (Sou­lever, puis déplacer vers le côté.)

Maintenir le cadre pendant la dépose des
vis.

3

3

3

4. Déposer les vis (4) du support d’axe
avant.

Avant de procéder au montage, s’assurer
de la présence et du bon état de toutes les
pièces. Contrôler à la fois les pièces dans
les cartons et celles sur le véhicule afin de
s’assurer qu’elles ne sont ni endom­magées, ni griffées et ne présentent aucun
autre défaut.

3

-1-

EMPLACEMENT DES

PIÈCES

312

1. Boîte en carton 1

2. Boîte en carton 2

3. Emballage de film à bulles

4. Sac en plastique

5. Roue avant

54

-2-

Boîte en carton 1

1

2

3

4

6

7

5

8910

17. Vis à tête hexagonale à pans creux
(protection de bras de fourche) [d = 6
(0.24), L = 16 (0.63)]

18. Écrous à collerette (protection de bras
de fourche) [d = 6 (0.24)]

19. Vis à tête hexagonale à pans creux
(appui de garde-boue avant) [d = 6
(0.24), L = 16 (0.63)]

20. Vis à tête hexagonale à pans creux
(collier à pince de durite de frein avant)
[d = 6 (0.24), L = 10 (0.39)]

21. Vis à tête hexagonale à pans creux
(patte de bridage de durite de frein
avant) [d = 6 (0.24), L = 10 (0.39)]

22. Vis à collerette (patte de fixation de fil
de capteur de roue avant) [d = 6 (0.24),
L = 12 (0.47)]

Boîte en carton 2

1

1. Logement de capteur de roue avant

Emballage de film à bulles

11

12 13

14 15

16

17 18

19 20

21 22

1. Garde-boue avant

2. Protection de bras de fourche

3. Rétroviseurs

4. Trousse de réparation 2

5. Manuel du propriétaire

6. Sac en plastique

7. Support droit de garde-boue avant

8. Support de durite de frein avant

9. Support gauche de garde-boue avant

10. Patte de bridage de durite de frein
avant

11. Sac en plastique

12. Appuis de garde-boue avant

13. Collier de durit de frein avant

14. Porte-clé

15. Support du fil du capteur de la roue
avant

16. Sac en plastique

1

1. Entretoise épaulée (roue avant) [d = 22
(0.87)]

2. Vis à tête hexagonale à pans creux
(capteur de roue avant) [d = 6 (0.24), L
= 14 (0.55)]

Sac en plastique

1

1. Capteur de roue avant

Roue avant

1

1. Roue avant

2

-3-

LISTE DES MONTAGES, CONTRÔLES ET ENTRETIENS À EFFECTUER AVANT LA

LIVRAISON

VMX17(Y) 2009

Vérifier une nouvelle fois les points suivants après avoir effectué le montage et l'entretien avant livraison.

A: MONTAGE DES PIÈCES LIVRÉES DANS LA CAISSE

□ ROUE AVANT □ RÉTROVISEURS
□ GARDE-BOUE AVANT □ BATTERIE

B: COUPLE DE SERRAGE DES PIÈCES

□ Vis d'axe de roue avant 81 Nm (8.1 m•kg, 59 ft•lb)
□ Vis de pincement d'axe de roue avant 21 Nm (2.1 m•kg, 15 ft•lb)
□ Vis de fixation d'étrier de frein avant 35 Nm (3.5 m•kg, 25 ft•lb)
□ Vis (patte de fixation de fil de capteur de roue avant) 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Vis du capteur de roue avant 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Vis (appui de garde-boue avant) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Vis (protection de fourche) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Vis (patte de bridage de durite de frein avant) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Vis (collier à pince de durite de frein avant) 10 Nm (1.0 m•kg, 7.2 ft•lb)
□ Vis (couvercle de batterie) 3 Nm (0.3 m•kg, 2.2 ft•lb)
□ Vis (cache supérieur) 1.5 Nm (0.15 m•kg, 1.1 ft•lb)
□ Vis (cache supérieur) 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Vis (cache d'écran multifonction) 7 Nm (0.7 m•kg, 5.1 ft•lb)
□ Vis (selle du pilote) 7 Nm (0.7 m•kg, 5.1 ft•lb)

C: CHEMINEMENT DES FILS, CÂBLES, ETC.

□ Fixation de fil de capteur de roue avant □ Durit de frein avant
□ Câble positif de batterie □ Câble négatif de batterie

D: RÉGLAGES

□ CONTRÔLE ET CHARGEMENT DE LA BATTERIE □ PURGE DU CIRCUIT DES FREINS HYDRAULIQUES
□ CONTRÔLE DE LA PRESSION DE GONFLAGE DES PNEUS □ RÉGLAGE DU LEVIER D'EMBRAYAGE
□ CONTRÔLE DU NIVEAU D’HUILE MOTEUR □ CONTRÔLE DU NIVEAU DE LIQUIDE D’EMBRAYAGE
□ CONTRÔLE DU NIVEAU D’HUILE DE COUPLE CONIQUE

ARRIÈRE

□ CONTRÔLE DU NIVEAU DE LIQUIDE DE REFROIDISSE-

MENT

□ RÉGLAGE DU JEU DE CÂBLE DES GAZ □ RÉGLAGE DU COMBINÉ RESSORT-AMORTISSEUR AR-

□ RÉGLAGE DU FREIN AVANT □ RÉGLAGE DU FAISCEAU DE PHARE
□ RÉGLAGE DU CONTACTEUR DE FEU STOP SUR FREIN

ARRIÈRE

□ CONTRÔLE DU NIVEAU DU LIQUIDE DE FREIN

E: FONCTIONNEMENT ET PERFORMANCES

□ Contrôler le bon fonctionnement du phare, de l'éclairage des

compteurs et du feu arrière.

□ Contrôler le bon fonctionnement du feu stop. □ Contrôler le comportement des freins.
□ Contrôler le bon fonctionnement des clignotants et des té-

moins.

□ Contrôler le bon fonctionnement de l'avertisseur. □ Contrôler si l'échappement fuit (oui/non).

F: ACCESSOIRES, ETC. LIVRÉS AU CLIENT

□ Manuel du propriétaire □ Porte-clé
□ Trousse de réparation

□ PURGE DU CIRCUIT D’EMBRAYAGE HYDRAULIQUE

□ RÉGLAGE DES BRAS DE FOURCHE

RIÈRE

□ RÉGLAGE DE LA MONTRE NUMÉRIQUE

□ Contrôler le bon fonctionnement de l'indicateur au cadran du

compteur de vitesse.

□ Contrôler si le moteur produit des bruits anormaux (oui/non).

-4-

MONTAGES À EFFECTUER

Effectuer les montages dans l’ordre numérique donné. Toujours suivre l’ordre indiqué.

12 43

-5-

1. ROUE AVANT

J

8

7

35

J

8

8

35

8

G

H

81

5

7

B

21

11

D

1C

4 *

1V

1V

4

K

9

10

M

12

d = 14 (0.55), L =
23 (0.91)
d = 8 (0.31), L = 45
(1.77)

d = 10 (0.39), L =
71 (2.8)

d = 6 (0.24), L = 12
(0.47)

d = 6 (0.24), L = 14
(0.55)

L

7

7

I

21

6

C

6

6

I

2

1

F

F

1 Roue avant 1 S
2 Entretoise épaulée 1 V d = 22 (0.87)

Logement de capteur de

3

roue avant

4 Axe de roue avant 1 *

5 Vis d'axe de roue avant 1 *

Vis de pincement d'axe de

6

roue avant

7 Étrier de frein avant 2 *

8 Vis à collerette 4 *

Support du fil du capteur de

9

la roue avant

10 Vis à collerette 1 V

11 Capteur de roue avant 1 V

Vis à tête hexagonale à

12

pans creux

A: Nettoyer les disques de frein.
B: Nettoyer l'axe de roue avant.
C: Nettoyer l'entretoise épaulée.
D: Nettoyer le logement du capteur de roue avant.
E:

Veiller à ne pas mettre de la graisse sur les disques de frein
ni la surface intérieure des plaquettes de frein. Le cas
échéant, nettoyer à l'aide d'un chiffon imbibé de dissolvant.
Une surface de freinage sale risque de limiter la puissance
de freinage.

A,E

3

• En cas de contact avec du dissolvant, es-suyer immédiate­ment la roue dentée.

Ne pas actionner le levier de frein quand les étriers sont séparés
des disques de frein.

G: S'assurer d'aligner la fente du logement du capteur de roue

avant et la butée sur le fourreau de fourche.

H: Enduire d'une fine couche de graisse la surface de contact

des vis. Serrer la vis d'axe de roue avant au couple spécifié.

Vis d'axe de roue avant

81 Nm (8.1 m•kg, 59 ft•lb)

Avant de serrer la vis de pincement, pomper la fourche à
quelques reprises pour vérifier son bon fonctionnement.

I: Serrer les vis de pincement d'axe de roue au couple spécifié.

Vis de pincement d'axe de roue avant

21 Nm (2.1 m•kg, 15 ft•lb)

Se reporter à "COUPLES DE SERRAGE".

J: Serrer les vis de fixation d'étrier de frein avant au couple

spécifié.

Vis de fixation d'étrier de frein avant

35 Nm (3.5 m•kg, 25 ft•lb)

K: S'assurer que le repère "UP" et la flèche sur la fixation soient

dirigés vers le haut, et soient du côté intérieur.

L: Serrer la vis au couple spécifié.

Vis

7 Nm (0.7 m•kg, 5.1 ft•lb)

M: Serrer la vis du capteur de roue avant au couple spécifié.

Vis du capteur de roue avant

7 Nm (0.7 m•kg, 5.1 ft•lb)

Acheminer le fil du capteur de roue avant en se référant à la
section "CHEMINEMENT DES CÂBLES".

2. GARDE-BOUE AVANT

A,B

10

8

C

10

7

8

C

8

F

G

10

9

13

13

12

3

4

6

5

6

8

10

6

A,B

5

6

10

10

C

7

8

10

F: Soulever la roue avant et monter l'axe de roue avant. Veiller

à ce que la flèche sur le pneu soit dirigée dans la direction de
rotation de la roue.

• Éloigner tous types d'aimants (y compris doigts et tourne­vis magnétiques, etc.) de la roue dentée.

• Ne pas laisser tomber, heurter ni faire subir de choc.

-6-

9

11

E

10

2

1

D

8

C

10