Yamaha VMX17YB (2009) Assembly Manual

2009

MOTORCYCLE / MOTOCYCLETTE

ASSEMBLY MANUAL / MANUEL

D'ASSEMBLAGE

Model : VMX17YB

2S3281077000

*2S3281077000*

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.

VMX17Y

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.

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

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

20. Flange nuts (front fork guard) [d = 6

2

4

(0.24)]

21. Hexagon socket bolts (front fender
stay) [d = 6 (0.24), L = 16 (0.63)]

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

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

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

Carton box 2

6

7

5

8

9

10

11 12

13

14 15

16 17

18

19 20

1

1. Front wheel sensor housing

Bubble wrap pack

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

2

21 22

23 24

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. Plastic bag

9. Front brake hose bracket

10. Plastic bag

11. Left front fender bracket

12. Front brake hose holder

13. Plastic bag

14. Front fender stays

15. Front brake hose clamp

16. Key holder

17. Front wheel sensor lead holder

18. Plastic bag

1. Front wheel sensor

Front wheel

1

1. Front wheel

-3-

SETUP AND PREDELIVERY CHECKLIST

VMX17Y

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

PRESSURE

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

YAMALUBE 4 (10W-40) or SAE 10W­40, YAMALUBE 4 (20W-50) 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-