free yamaha vmax service manual

Therefore, when the brake lever is squeezed, the hydraulic pressure in the brake master cylinder increases and the brake fluid is sent to the brake caliper. When this occurs, the inlet solenoid valve compresses the spring and closes the brake line from the brake master cylinder. At this time, the ABS ECU controls the opening of the inlet solenoid valve. As the inlet solenoid valve opens, the brake line from the brake master cylinder opens, allowing the brake fluid to be sent to the brake caliper. The ABS warning light comes on for 2 seconds while the ABS is performing a self-diagnosis, then goes off if there are no problems. If the ABS warning light flashes while riding, there is no problem with the function of the ABS. How- ever, the ABS ECU input has unstable factors. (For details, refer to “ABS TROUBLESHOOTING OUTLINE”. When the ABS is activated, the grip between the road surface and tires is close to the limit. This degree of intake vol- ume control gives both improved low to mid-range power, as well as improved power in the higher rpm range. ECU (engine control unit) 2. Throttle position sensor 17. Base map 3. Crankshaft position sensor 18. Idle speed control 4. Speed sensor 19. Calculated throttle valve opening angle 5. Coolant temperature sensor 20. The indicator light flashes once every two sec- onds to show that it has been deactivated. The 4. Push “RESET”. indicator light goes off after this menu is exited. Push “SELECT”. Pushing “SELECT” and “RE- light or coolant temperature warning light SET” for at least three seconds, changes the comes on, the Normal mode is automatically display to the Normal mode. Self-diagnosis device 1. Fault code display This model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light comes on and the display indicates a two-digit fault code. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments.

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Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat. This information will be needed to order spare parts. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. When the brakes are applied, wheel speed and chassis speed are reduced.The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly. Rear brake caliper 3. Front brake master cylinder 11. Rear wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13. As the sensor rotor rotates, the Hall element in the Hall IC installed in the wheel sensor generates pulses. The pulse frequency, which is proportional to the magnetic flux density, is converted into a wave in the Hall IC so that it can be output. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU. As shown in the block following diagram, the ABS ECU receives wheel sensor signals from the front and rear wheels and also receives signals from other monitor circuits. 4 5 6 18 19 1.

Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock. ECA13420 NOTICE Clutch fluid may damage painted surfaces or plastic parts. Unfiltered air will cause Refer to “GENERAL CHASSIS” on page 4-1. rapid wear of engine parts and may damage 2. Before checking the coolant level, wait a few minutes until the coolant has settled. M MMM M MMM M MMM M MMM M MMM Direction “b” a. Fill the brake master cylinder reservoir or Brake light comes on later.If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. Never go beyond the maximum or minimum Direction “b” adjustment positions.Recommended lubricant Lithium-soap-based grease EAS2S31015 CHECKING THE SIDESTAND. Refer to “ELECTRICAL COMPONENTS” on page 8-117. Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left.ECA2S31007 NOTICE To prevent damaging the wheel or wheel sensor Keep magnets (including magnetic pick-up rotor, place a rag “2” between the screwdriver tools, magnetic screwdrivers, etc.) away and the surface of the wheel or rotor. Refer to “MAINTENANCE OF THE FRONT f. YM-01525 Radial wheel runout limit ECA2S31017 1.0 mm (0.04 in) NOTICE Lateral wheel runout limit The bearing retainer has left-handed 0.5 mm (0.02 in) threads. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS)”. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston. EWA14100 WARNING Disc brake components rarely require disas- sembly.Always install new brake pads and new brake f. EAS22350 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Refer to “BLEEDING THE HYDRAULIC Recommended fluid BRAKE SYSTEM (ABS)”. M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Illustration pages Oil filter wrench 3-11 90890-01426 YU-38411 Oil pressure gauge set 3-12 90890-03120 Oil pressure adapter B 3-12 90890-03124 Steering nut wrench 3-27, 4-81 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder (24 mm) 4-23, 4-27, 90890-01328 4-48, 4-50. Illustration pages Piston pin puller set 5-82 90890-01304 Piston pin puller YU-01304 YU-01304 Damper spring compressor 5-109, 5-111 90890-04090 Middle drive shaft nut wrench (55 mm) 5-110 90890-04054 Offset wrench 55 mm YM-04054 YM-04054 Middle gear backlash tool 5-113 90890-04080. Illustration pages Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-13 90890-04132 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-13 90890-04058 Bearing driver 40 mm YM-04058 Pressure gauge 7-5, 7-14. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. The difference in vacuum pres- sure between the throttle bodies should not exceed 1.33 kPa (10.

Clutch fluid Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM”. Refer to “BLEEDING THE HYDRAULIC Recommended fluid CLUTCH SYSTEM”. Refer to “CHECKING THE CLUTCH FLUID LEVEL”. Instead, replace the bolt with a new “42”. Al- ways install new bolts. f. Clean the connecting rod bolts. g. After installing the big end bearing, assemble the connecting rod and connecting rod cap without installing them onto the crankshaft. Crankcase Refer to “CRANKCASE” on page 5-73. Refer to “CONNECTING RODS AND PIS- Connecting rod caps TONS” on page 5-81. Balancer shaft Balancer shaft journal upper bearing Balancer shaft journal lower bearing Crankshaft. J1 J2 J3 J4 c. Install the balancer shaft journal upper bear- ings “1” and the balancer shaft into the upper crankcase. Align the projections “a” on the balancer shaft journal upper bearings with the notches “b”. Refer to “CRANKCASE” on page 5-73. g. Remove the lower crankcase and the balanc- B 8 8 8 7 er shaft journal lower bearings. Crankcase Refer to “CRANKCASE” on page 5-73.Bearing Washer 1st wheel gear Collar 4th wheel gear Circlip Toothed washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer. Crankcase Refer to “CRANKCASE” on page 5-73. Middle drive pinion gear bearing retainer Refer to “ALIGNING THE MIDDLE GEAR”. Apply compressed air to the rear of the radia- tor. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure. Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03176 YM-03176 d. Start the engine. e. Measure the fuel pressure.This is because the electric current from the ignition coils does not flow to the ECU when both the gear position switch (neutral circuit) and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark. Refer to “CHECKING THE FUS- ES”. Refer to “CHECKING THE Replace the gear position switch. SWITCHES” on page 8-121.

ECA2S31024 NOTICE ECA2S31031 Unless necessary, avoid removing and in- NOTICE stalling the brake pipes of the hydraulic unit When removing the brake hoses, cover the assembly. First, tighten the bolts on the front side of the EWA13120 handlebar holder, and then on the rear side. WARNING Securely support the vehicle so that there is no danger of it falling over. Align the projection “a”. The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. WARNING EWA13120 WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Be- Securely support the vehicle so that there is fore handling the rear shock absorber or gas no danger of it falling over. Repeat vated and then spin the rear wheel.Final gear backlash is in- Thinner shim creased. Final gear backlash is de- Thicker shim creased. Final drive pinion gear shims Thickness (mm) Ring gear bearing thickness 0.30 0.40 0.50 15.90 mm (0.63 in) Since the final drive pinion gear shims are Example: only available in 0.10 mm increments, round If the ring gear bearing housing is marked off to the hundredths digit. To tighten the bearing retainer, turn it coun- terclockwise.Drive shaft Refer to “SHAFT DRIVE”. Left rider footrest assembly Sidestand switch coupler Disconnect. INSTALLING THE CAMSHAFTS c. Squeeze timing chain tensioner clip 2 “1”, and then push the timing chain tensioner rod Front cylinders-intake side “3”. Refer to the identification marks sioner.After all of the bolts are fully loosened, remove them. 2. Tighten the bolts using the following procedure. M MMM M MMM M MMM M MMM M MMM a. Cylinder heads Refer to “CYLINDER HEADS” on page 5-26. Valve lifter Valve pad Valve cotter Valve spring retainer. Free length (intake) 40.78 mm (1.61 in) Limit b. Engine oil Refer to “CHANGING THE ENGINE OIL” on page 3-11.

ER-3 ECU internal malfunction (output signal error): data from the Item ECU cannot be received correctly. Fault code No. ER-4 ECU internal malfunction (input signal error): non-registered Item. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal are even slightly applied, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction. The ABS warning light flashes every 0.5 second if a fault code for a past malfunction is not stored in the memory of the ABS ECU. The ABS warning light flashes quicker if a fault code is displayed on the multi-function display. ABS-11 Symptom Front wheel sensor signal is not received prop- ABS-25 erly. Check for looseness.Check for looseness.ABS-13 Symptom Incorrect signal from the front wheel sensor is ABS-26 detected. Check for looseness.ABS-14 Symptom Incorrect signal from the rear wheel sensor is ABS-27 detected. Check for looseness.ABS-15 Symptom No continuity in the front wheel sensor circuit.ABS-15 Symptom No continuity in the front wheel sensor circuit. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and front wheel sensor coupler, and then delete the fault. ABS-16 Symptom No continuity in the rear wheel sensor circuit.ABS-16 Symptom No continuity in the rear wheel sensor circuit. If the above items were per- formed and no malfunctions were found, connect the ABS ECU coupler and rear wheel sensor coupler, and then delete the fault. ABS-18 Symptom Missing pulses detected in the rear wheel sen- ABS-46 sor signal.ABS-22 Symptom Start switch signal is not received properly (start switch circuit or start switch monitor cir- cuit).ABS-24 Symptom Brake light signal is not received properly while vehicle is traveling (brake light circuit, or front or rear brake light switch circuit).ABS-31 Symptom Solenoid relay is defective. Power is not supplied to the solenoid relay.

Turn the main Refer to “CHECKING AND switch to “ON”. ABS-32 Symptom Hydraulic unit solenoid relay is short-circuited.ABS-33 Symptom ABS motor is defective. Power is not supplied to the ABS motor.EWA2S31023 WARNING Only use genuine Yamaha parts.EWA2S31023 WARNING Only use genuine Yamaha parts.ABS-42 Symptom Rear wheel will not recover from the locking ten- ABS-47 dency even though the signal is continuously transmitted from the ABS ECU to release the hy- draulic pressure.ABS-43 Symptom Incorrect signal from the front wheel sensor is detected. Check for looseness.ABS-44 Symptom Incorrect signal from the rear wheel sensor is detected. Check for looseness.ABS-53 Symptom Power voltage is too low.ABS-54 Symptom Power voltage is too low.ABS-56 Symptom Hydraulic unit sensor power monitor circuit is abnormal.ABS-63 Symptom Front wheel sensor power is abnormal.ABS-64 Symptom Rear wheel sensor power is abnormal.If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads. Therefore, the EAS28030 CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals.If too current written on the battery, this type of battery high, the battery will be over-charged.If the continuity reading is incorrect, re- (between “3” and “4”) place the relay. Relay unit (fuel pump relay) Pocket tester 90890-03112 Analog pocket tester YU-03112-C 1. M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the spark L LLL L LLL L LLL L LLL L LLL plug. 2. Check: b. It should 3. Fuel level warning light Black 57. Coolant temperature warning VMX17Y(C) 2009 Brown light 1. AC magneto Chocolate 58. Left turn signal indicator light 3.

Refer to “CHECKING THE Replace the sidestand switch.Refer to “CHECKING THE FUS- ES”. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 8-121. Refer to “CHECKING THE Replace the gear position switch. SWITCHES”. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system. If no malfunction is detected in the sensors 1. The num- ber is cumulative and does not reset each time the wheel is stopped. Illuminates the engine trou- ble warning light. Actuates the air induction system solenoid five times at Check the operating sound. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display ac- cording to the reinstatement method. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor.Item Intake air pressure sensor: open or short circuit detected. Refer to “CHECKING THE INTAKE AIR PRESSURE SENSOR” on page 8-139. Reinstatement method Turning the main switch to “ON”. Item Throttle position sensor: open or short circuit detected.Item EXUP servo motor circuit: open or short circuit detected.Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.Intake air pressure sensor or atmospheric pressure sensor: when the main switch is turned to “ON”, the atmospheric pres- Item sure sensor voltage and intake air pressure sensor voltage dif- fer greatly.Item Intake air temperature sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.

D:05 Meter display Displays the intake air temperature. Compare the actually measured intake air temperature with the Checking method meter display value. Item Atmospheric pressure sensor: open or short circuit detected.Latch up detected. Item No normal signal is received from the lean angle sensor. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.Item Injector: open or short circuit detected.Item Lean angle sensor: open or short circuit detected.Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected in the neutral circuit of the gear position switch. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Rear wheel sensor: no normal signals are received from the rear wheel sensor. Item Gear position switch: open or short circuit is detected in the neutral circuit of the gear position switch. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Fuel system voltage: the ECU is unable to monitor the battery Item voltage (an open or short circuit in the line to the ECU).Item Power supply to the fuel injection system is not normal.Item Accelerator position sensor: open or short circuit detected. Refer to “CHECKING THE ACCELERATOR POSITION SENSOR” on page 8-138. Reinstatement method Turning the main switch to “ON”. Throttle servo motor: open or short circuit detected. Item Defective throttle servo motor. Malfunction in ECU (servo motor driving system). Reinstatement method Turning the main switch to “ON”. Fault code No. Engine idling stop: engine has been left idling. (The ECU auto- Item matically stops the engine after 20 minutes if it is left idling.) Able to start engine. ER-2 ECU internal malfunction (output signal error): no signals are Item received from the ECU within the specified duration. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Meter display —.

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