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Yamaha 2003 VMAX Owner's Manual

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1. AN VMAX pc EAU03438 A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 EAU00002 INTRODUCTION Congratulations on your purchase of the Yamaha VMX12 VMX12C This model is the result of Yamaha s vast experience in the production of fine sporting touring and pacesetting racing machines It represents the high degree of craftsmanship and reliability that have made Yamaha a leader in these fields This manual will give you an understanding of the operation inspection and basic maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcycle To maintain these high standards it is important that you and your Yamaha dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual Wile eb COP rr ce Particularly important information is distinguished in this manual by the following notations A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING F
2. H Handlebar switches Headlight bulb replacing Helmet holder High beam indicator light Horn switch l Identification numbers Ignition circuit cut off system Indicator and warning lights K Key identification number L Labels location M Main switch Maintenance and lubrication periodic Maintenance emission control system Maintenance periodic Maintenance record Model label N Neutral indicator light Noise regulation o Oil level warning light P Parking Part locations Pre operation check list R Rear suspension lubricating Rider seat S Safety defects reporting Safety information Shifting Decelerating Shift points Starting out and accelerating Shift pedal Shock absorber assemblies adjusting 3 12 Sidestand Spark plugs checking Specifications Speedometer unit Starter choke lever Starting and warming up a cold engine 5 1 Starting a warm engine Start switch Steering checking Steering lock Storage Suspension settings matching front and rear T Tachometer Throttle cable free play adjusting Throttle grip and cable checking and lubricating Tool kit Troubleshooting Troubleshooting charts Turn signal indicator light Turn signal light bulb or the tail brake light bulb replacing Turn signal switch V Valve clearance adjusting Vehicle identification number W Warranty extended Warranty limited Wheel bearings checking Wheel front I
3. To check the condition Securely support the motorcycle so that there is no danger of it falling over EW000115 Check the inner tubes for scratches damage and excessive oil leakage 6 33 To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC000098 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU00794 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground Securely support the motorcycle so that there is no danger of it falling over EWO000115 PERIODIC MAINTENANCE AND MINOR REPAIR 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steer ing 6 34 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01144 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion chart If there is
4. duced discoloring of stainless steel exhaust systems can be re moved through polishing To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces Use spray oil as a universal clean er to remove any remaining dirt Touch up minor paint damage caused by stones etc Wax all painted surfaces Let the motorcycle dry completely before storing or covering it EWA00031 Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor nering behavior 7 3 ECA00013 CAUTION NOTE Consult a Yamaha dealer for advice on what products to use Apply spray oil and wax spar ingly and make sure to wipe off any excess Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product Avoid using abrasive polishing compounds as they will wear away the paint MOTORCYCLE CARE AND STORAGE Storage Long term a Remove the spark plug caps Before storing your motorcycle for and spark plugs Short term several months b Pour a teaspoonful of engine Always store your motorcycle in a cool 1 Follow all the instructions in the oil into eac
5. then remove it ECA00062 CAUTION Do not push the brake pedal after the wheel has been removed togeth er with the brake disc otherwise the brake pads will be forced shut EAU04362 To install the rear wheel 1 Apply a light coating of lithium soap based grease to the splines of the final gear case and wheel hub 2 Install the wheel brake caliper bracket spacer and wheel axle 3 Install the brake caliper by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc 6 45 Connect the brake torque rod to the brake caliper bracket by in stalling the bolt and the nut Install the axle nut and then slight ly tighten it Take the motorcycle off the cen terstand so that the rear wheel is on the ground Tighten the rear wheel axle pinch bolt the axle nut the brake caliper bolts and the brake torque rod nut to the specified torques Tightening torques Axle nut 150 Nm 15 0 m kgf 108 ft lbf Brake caliper bolt 40 Nm 4 0 m kgf 29 ft Ibf Brake torque rod nut 23 Nm 2 3 m kof 17 ft Ibf Rear wheel axle pinch bolt 16 Nm 1 6 m kgf 11 ft Ibf Install the brake torque rod cotter pin PERIODIC MAINTENANCE AND MINOR REPAIR EW000124 EAU03087 Troubleshooting Always use a new cotter pin Although Yamaha motorcycles receive a thorough inspection before shipment from the
6. 0 7 Imp gal 0 8 US gal ECA00104 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause se vere damage to internal engine parts such as the valves and piston rings as well as to the exhaust sys tem Your Yamaha engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems INSTRUMENT AND CONTROL FUNCTIONS 1 Starter choke lever EAUOO0211 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction to turn on the starter choke Move the lever in direction to turn off the starter choke 3 8 INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering 1 Open the steering lock cover and then insert the key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves o
7. EAU04247 VMX12R VMX12RC OWNER S MANUAL 2002 by Yamaha Motor Corporation U S A 1st edition April 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 20 EAU00009 TABLE OF CONTENTS 1 SAFETY INFORMATION 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX Safe riding Protective apparel Modifications Loading and accessories Gasoline and exhaust gas Location of important labels _Q SAFETY INFORMATION 7 MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DE PENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BE FORE RIDING THIS MOTORCYCLE HE OR SHE SHOULD 1 2 3 4 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER S MANUAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation
8. See page 6 9 for panel removal and installation procedures Observe these precautions e When checking the fluid level make sure that the top of the brake or clutch fluid reservoir is level e Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Recommended brake and clutch fluid DOT 4 brake fluid 6 29 TIRLL 1 Panel B 2 Minimum level mark e Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch per formance e The brake or clutch fluid reservoir diaphragm will lose its shape from the negative pressure if the fluid level goes down too far Be sure to return the diaphragm to its original shape before installing it into the brake or clutch fluid reservoir e Be careful that water does not enter the brake or clutch fluid reservoir when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock e Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to gradually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU03984 Changing the brake and clutch fluids Have a Yamaha dealer change the bra
9. 18 Imp qt 0 21 US qt 3 05 L 2 68 Imp qt 3 22 US qt Dry element UNLEADED GASOLINE ONLY 15 L 3 3 Imp gal 4 0 US gal 3 L 0 7 Imp gal 0 8 US gal MIKUNI BDS35 x 4 DPR8EA 9 NGK or X24EPR U9 DENSO 0 8 0 9 mm 0 03 0 04 in Wet multiple disc Spur gear 1 775 Shaft drive 2 851 Constant mesh 5 speed Operation Gear ratio ist 2nd 3rd 4th 5th Chassis Frame type Caster angle Trail Tires Front Type Size Manufacturer model Rear Type Size Manufacturer model SPECIFICATIONS Left foot 2 529 1 772 1 347 1 076 0 928 Double cradle 29 119 mm 4 69 in Tubeless tire 110 90 18 M C 61V 110 90 18 61V Bridgestone G525AW Dunlop F20 Tubeless tire 150 90 15 M C 74V Bridgestone G526BW Dunlop K525 SPECIFICATIONS Maximum load VMX12 VMX12C Tire air pressure measured on cold tires Up to 90 kg 198 Ib Front Rear 90 kg 198 Ib maximum Front Rear High speed riding Front Rear 216 kg 476 Ib 215 kg 474 Ib 225 kPa 2 25 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi Total weight of rider passenger cargo and accessories Wheels Front Type Size Rear Type Size Brakes Front Type Cast wheel 18 x MT 2 15 Cast wheel 15M C x MT 3 50 Dual disc brake Operation Fluid Rear Type Operation Fluid
10. Wheel bearings smooth rotation Check specific gravity Battery and breather pipe for Y Y proper operation Check and clean or replace if necessary Sidestand switch Since these items require special tools data and technical skills have a Yamaha dealer perform the service NOTE From 24 000 mi 37 000 km or 36 months repeat the maintenance intervals starting from 4 000 mi 7 000 km or 6 months EAU03892 EAU03907 NOTE e The air filter needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake and clutch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylinder always change the fluid Regularly check the brake and clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses every four years or if cracked or damaged PERIODIC MAINTENANCE AND MINOR REPAIR 1 Cowling A 1 Unlock 1 Holder x 2 2 Panel A de 2 Projection x 2 3 Panel B Cowling A To install the cowling 1 Align the holders under the cowl ing with the projections on the frame 2 Push down on the rear of the cowl ing until it locks in place 3 Remove the key from the lock i eavossi6 To remove
11. distribution or aerodynamic changes If accessories are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum b Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic effects Wind may attempt to lift the motorcycle or the motorcycle may become unstable in cross winds These accessories may also cause instability when passing or being passed by large ve hicles c Certain accessories can displace the operator from his or her normal riding position This improp er position limits the freedom of movement of the operator and may limit control ability therefore such accessories are not recommended Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b Take care not to spill any gasoline on the engine or exhaust system when refueling c Never refuel while smoking or in the vicinity of an open flame Never start the engine or let it run for any length of time in a closed area The exhaust fumes are poi sonous and may cause loss of consciousness and death within a short time Always operate your motorcycle in an area that has adequate ventilation Al
12. other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be e You don t have to pay anything for covered repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs 9 9 e In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period e Y E S coverage is honored at any authorized Yamaha dealer nationwide e Y E S coverage is transferable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service EAUO1063 CONSUMER INFORMATION We urge you
13. place To make the brake light come on earlier turn the adjusting nut in direction 8 To make the brake light come on later turn the adjusting nut in direction 6 28 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Brake pad wear indicator EAU00715 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart Each brake pad is provided with a wear indicator which allows you to check the brake pad wear without having to disassemble the brake To check the brake pad wear check the position of the wear indicator while applying the brake If a brake pad has worn to the point that the wear indi cator almost touches the brake disc have a Yamaha dealer replace the brake pads as a set PERIODIC MAINTENANCE AND MINOR REPAIR 1 Minimum level mark EAU04169 Checking the brake and clutch fluid levels Insufficient brake fluid may allow air to enter the brake or clutch systems pos sibly causing them to become ineffec tive Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake flu id level may indicate worn brake pads and or brake system leakage If the brake level is low be sure to check the brake pads for wear and the brake sys tem for leakage 1 Minimum level mark NOTE The rear brake fluid reservoir is located behind panel B
14. play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 1 Battery 2 Battery breather hose 3 Pass through the cable guide EAU04864 Battery A poorly maintained battery will cor rode and discharge quickly The elec trolyte level battery lead connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart 6 35 1 Maximum level mark 2 Minimum level mark To check the electrolyte level 1 Place the motorcycle on the cen terstand NOTE Make sure that the motorcycle is posi tioned straight up when checking the electrolyte level 2 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minimum level mark continue with the following steps Remove the rider seat See page 3 9 for rider seat removal and installation procedures PERIODIC MAINTENANCE AND MINOR REPAIR 7 A LL ds i 1 Starter moter lead black 2 Positive battery lead red 3 Negative battery lead 5 Disconnect the negative battery lead from the battery 6 Disconnect the positive battery lead and the starter motor lead from the starter motor relay 6 36 1 Ignition coil assembl
15. the rider seat backrest forward 3 6 1 Unlock 2 Insert the key into the lock and then turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be removed INSTRUMENT AND CONTROL FUNCTIONS To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark on the cap facing forward 2 Turn the key counterclockwise to the original position and then re move it 3 Slide the rider seat backrest rear ward and push it down NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked Make sure that the fuel tank cap is properly installed before riding Ewoo0024 1 Fuel tank filler tube 2 Fuel level EAUO3753 Fuel Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown e Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands e Avoid spilling fuel on the hot engine EW000130 3 7 EAU00185 CAUTION _ _ _ _ o o Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU04265 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity Total amount 15 L 3 3 Imp gal 4 0 US gal Reserve amount 3 L
16. to act now You ll get the excellent benefits of TRIP coverage right away and you ll rest easy knowing you ll have strong factory backed protection even after your Yamaha Limited Warranty expires You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note YAMAHA EXTENDED SERVICE If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 A Accessories and replacement parts Air filter element cleaning Brake and clutch fluid levels checking 6 29 Brake and clutch fluids changing Brake and clutch levers checking and lubricating Brake and shift pedals checking and lubricating Brake lever Brake lever free play adjusting Brake light switch rear adjusting Brake pads checking Brake pedal Brake pedal position adjusting C Centerstand and sidestand checking and lubricating Clutch lever Clutch lever free play Coolant Changing Checking Coolant temperature gauge Cowling and panels removing and installing D Dimmer switch E Engine break in Engine oil and oil filter cartridge Engine stop switch F Final gear oil Front fork adjusting Front fork checking Fuel level warning light Fuel reserve switch Fuel tank cap Fuses replacing
17. within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect this inspection and registration must take place within ten 10 days after transfer An inspection and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 50cc or greater that the vehi cle is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty ENGINE DISPLACEMENT 50cc to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or f
18. 3 kg 624 Ib 284 kg 626 Ib Liquid cooled 4 stroke DOHC V type 4 cylinder 1 198 cm 76 x 66 mm 3 0 x 2 6 in 10 5 1 Electric starter Wet sump Engine oil Type 0 20 Recommended engine oil classification CAUTION 10 EAU01038 10 30 50 70 90 110 130 F I tol nal YAMALUBE 4 10W 30 ior SAE 10W 30 Y MALUBE 4 20W 20 ior SAE 20W 40 10 20 30 40 50 C API Service SE SF SG or higher In order to prevent clutch slippage since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel specification of CD or oils of a higher quality than specified In addition do not use oils la beled ENERGY CONSERVING II or higher Quantity Without oil filter cartridge replacement With oil filter cartridge replacement Total amount dry engine 3 2 L 2 82 Imp qt 3 38 US qt 3 4 L 2 99 Imp qt 3 59 US qt 4 L 3 52 Imp qt 4 23 US qt Final gear oil Type Quantity Cooling system capacity total amount Air filter Fuel Type Fuel tank capacity Fuel reserve amount Carburetor Manufacturer Model x quantity Spark plug Manufacturer model Gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Hypoid gear oil SAE80 API GL4 or multi grade hypoid gear oil SAE80W 90 0 2 L 0
19. 5 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 psi 90 kg 198 Ib maximum 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi High speed riding Maximum load Total weight of rider accessories 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm 36 psi 216 kg 476 Ib VMX12 215 kg 474 Ib VMX12C passenger cargo and 6 23 EW000083 Proper loading of your motorcycle is important for several characteris tics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure the total weight of the cargo rider passenger and accessories cowling saddlebags etc if approved for this model does not exceed the maximum load of the motorcycle Operation of an over loaded motorcycle could cause tire damage an accident or even injury 1 Tire sidewall 2 Tire wear indicator a Tire tread depth Tire inspection Always check the tires before operating the motorcycle If a tire tread shows crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewal
20. DATA KNOWLEDGE AND EQUIPMENT YAMAHA DEAL ERS ARE TRAINED AND EQUIPPED TO PERFORM THESE PARTICULAR SERVICES 6 1 EAU00462 1 Owner s tool kit 2 Rider seat backrest EAU04823 Owner s tool kit The tool kit is located inside the storage compartment behind the rider seat backrest See page 3 9 for an expla nation on moving the rider seat back rest forward and back PERIODIC MAINTENANCE AND MINOR REPAIR EW000062 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes The service information included in this manual and the tools provided in the owners tool kit are intended to assist you in the performance of preventive maintenance and minor repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perform it for you 6 2 PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance chart for emission control system ROUTINE INITIAL ODOMETER READINGS EAU00471 600 mi 1 000 km 4 000mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months Valve
21. E SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle b The passenger should always hold onto the operator the seat strap or grab bar if equipped with both hands and keep both feet on the passenger footrests c Never carry a passenger unless he or she can firmly place both feet on the passenger footrests Never ride under the influence of alcohol or other drugs This motorcycle is designed for on road use only It is not suitable for off road use 1 2 N SAFETY INFORMATION Protective apparel The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries 1 Always wear an approved helmet 2 Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vi sion that could delay seeing a hazard 3 The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abra sions or lacerations 4 Neve
22. FUEL TANK CAUTION Read owner s manual before servicing battery CANISTER i TO ATMOSPHERE Electrolyte will damage metal parts or paint If electrolyte spills wash area with fresh 4YN 21686 00 water immediately Be sure to connect breather hose after installing battery 3JL 28177 A0 5 WARNING PASS LEAD WIRES THROUGH HOLE as shown A short circuit could result from improper routing This could cause the engine to stop running and lights to fail which could result in an accident TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 225 kPa 2 25 kgf cm 33 psi REAR 225 kPa 2 25 kgf cm 33 psi 90 kg 198 Ibs maximum load FRONT 225 kPa 2 25 kgf cm 33 psi REAR 250 kPa 2 50 kgf cm 36 psi 5BN 21668 00 3JP 2415H A0 1 8 Left view Right view Controls and instruments DESCRIPTION Left view 1 Clutch fluid reservoir 2 Air filter element 3 Fuse box 4 Main fuse box 5 Owner s tool kit 6 Shock absorber assembly spring preload adjusting ring page 3 13 7 Shock absorber assembly damping force adjusting knob 8 Helmet holder 9 Shift pedal 10 Starter choke lever 2 1 EAUO0026 page 3 13 page 3 10 page 3 5 page 3 8 Right view 21 20 19 18 11 Fuel tank cap 12 Battery 13 Cool
23. IC MAINTENANCE AND MINOR REPAIR NOTE If any spark plug shows a distinctly dif ferent color the engine could be defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle 3 Check each spark plug for elec trode erosion and excessive car 1 Spark plug wrench bon or other deposits and replace 4 Spark plug gap it if necessary 2 Remove the spark plug as shown b To install a spark plug with the spark plug wrench includ 1 Measure the spark plug gap with a ed in the owner s tool kit wire thickness gauge and if nec essary adjust the gap to specifica Specified spark plug DPR8EA 9 NGK or X24EPR U9 DENSO To check the spark plugs tion 1 Check that the porcelain insulator around the center electrode on Spark plug gap each spark plug is a medium to 0 8 0 9 mm 0 03 0 04 in light tan the ideal color when the motorcycle is ridden normally 2 Checkthat all spark plugs installed in the engine have the same color 2 Clean the surface of the spark plug gasket and its mating sur face and then wipe off any grime from the spark plug threads 3 Install the spark plug with the spark plug wrench and then tight en it to the specified torque 6 10 PERIODIC MAINTENANCE AND MINOR REPAIR Tightening torque Spark plug 18 Nm 1 8 m kgf 13 ft Ibf NOTE If a torque wrench is not available when installing a spark plug
24. NHTSA in addition to notifying Yamaha Motor Corporation U S A If NHTSA receives similar complaints it may open an investigation and if it finds that a safety defect exists in group of vehicles it may order a recall and remedy campaign However NHTSA cannot become involved in individual problems between you your dealer or Yamaha Motor Corporation U S A To contact NHTSA you may either call the Auto Safety Hotline toll free at 1 800 424 9393 or 366 0123 in Washington D C area or write to NHTSA U S Department of Transportation Washington D C 20590 You can also obtain other informa tion about motor vehicle safety from the Hotline 9 3 CONSUMER INFORMATION EAUO1053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or rendering inoperative by any person other than for purposes of maintenance repair or replacement of any device or element of design incorporated into any new ve hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2 the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust p
25. NOR REPAIR 1 Radiator cap 1 Coolant drain cock 1 Water pump drain bolt 2 Position indicator 4 Remove the radiator cap 6 Remove the water pump drain bolt EWO00067 5 Turn the coolant drain cock to UN Never attempt to remove the radia tor cap when the engine is hot to drain the water pump housing 6 18 1 Screw x 4 7 Remove the cylinder drain plug covers on the outside of the cylin der blocks by removing the Screws PERIODIC MAINTENANCE AND MINOR REPAIR 1 Rubber coolant drain plug x 4 8 10 NOTE Remove the rubber coolant drain plugs to drain the coolant from the engine After the coolant is completely drained thoroughly flush the cool ing system with clean tap water Install the water pump drain bolt and then tighten it to the specified torque Check the washer for damage and re place it if necessary 6 19 Tightening torque 11 NOTE Water pump drain bolt 43 Nm 4 3 m kgf 31 ft lbf Install the rubber coolant drain plugs and then install the cylinder drain plug covers Check the rubber plugs for damage and replace them if necessary 12 13 14 Turn the coolant drain cock to OFF Pour the recommended coolant into the reservoir to the maximum level and then install the cap Pour the recommended coolant into the radiator until it is full Antifreeze water mixture ratio 1 1 Recommended antifreez
26. Replacing a turn signal light bulb or the tail brake light bulb 6 41 Front wheel eeeeeeeeeeeeeenn 6 42 Rear wheel rte te t e ette 6 44 Troubleshooting esee 6 46 Troubleshooting charts ssssssss 6 47 PERIODIC MAINTENANCE AND MINOR REPAIR EAU01790 Safety is an obligation of the owner Periodic inspection adjustment and lu brication will keep your vehicle in the safest and most efficient condition pos sible The most important points of motorcycle inspection adjustment and lubrication are explained on the follow ing pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establishment or individual that is certified if applicable EW000060 WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU00467 PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON TROL ARE GROUPED SEPARATE LY THESE SERVICES REQUIRE SPECIALIZED
27. Suspension Front Rear Spring shock absorber Front Rear Wheel travel Front Rear Electrical system Ignition system Charging system Type Standard output Battery Model Voltage capacity Headlight type Right hand DOT 4 Single disc brake Right foot DOT 4 Telescopic fork Swingarm Coil air spring oil damper Coil spring oil damper 140 mm 5 5 in 100 mm 3 9 in T C I digital A C magneto 14 V 22 5 AQ 5 000 r min YB16AL A2 12 V 16 Ah Quartz bulb halogen SPECIFICATIONS Bulb voltage wattage x quantity Headlight 12 V 60 55 W x 1 Tail brake light 12 V 8 27 W x2 Front turn signal position light 12V 27 8W x2 Rear turn signal light 12V 27W x2 Meter lighting 14V 3Wx2 Neutral indicator light 14V 3W x 1 High beam indicator light 14V 3Wx1 Turn signal indicator light 14V 8W x1 Fuel level warning light 14V 3Wx1 Oil level warning light 14V 3W x1 Fuses Main fuse 30A Headlight fuse 15A Signaling system fuse 10A Radiator fan fuse 10A Ignition fuse 10A Identification numbers Key identification number Vehicle identification number Model label Reporting safety defects Motorcycle noise regulation Maintenance record YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY YAMAHA EXTENDED SERVICE Y E S CONSUMER INFORMATION EAUO2944 Identification numbers Record the key identification number vehicle identification number and mod el label informati
28. a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible 4 Install the spark plug cap To carburetor To atmosphere Vent hose EAU01796 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Check each hose connection Check each hose and canister for cracks or damage Replace if damaged e Make sure the vent hose is not blocked Clean it if necessary 6 11 EAU04623 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check the engine oil level 1 Place the motorcycle on the cen terstand NOTE Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off PERIODIC MAINTENANCE AND MINOR REPAIR 1 Engine oil level check window 1 Engine oil filler cap 1 Engine oil drain bolt 2 Maximum level mark i s og 3 Minimum level mark To change the engine oil with or 3 Remove the engine oil filler cap without oil filter
29. ailure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person inspecting or repairing the motorcycle CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold e Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this manual If you have any questions concerning this manual please consult your Yamaha dealer IMPORTANT MANUAL INFORMATION EW000000 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTOR CYCLE DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE IMPORTANT MANUAL INFORMATION AFFIX DEALER LABEL HERE
30. ainst the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name V I N frame number dealer number or dealer s name as it is shown on your warranty card your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 Attention Warranty Department This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law CONSUMER INFORMATION YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service Y E S e Y E S is designed and administered by Yamaha Motor Corporation to provide maximum owner satisfaction You get uninterrupted factory backed coverage for extra peace of mind e Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period e Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts orthe drive train like many
31. akes to slow the motorcycle Shift the transmission into first gear when the motorcycle reaches 20 km h 12 5 mi h If the engine is about to stall or runs very rough ly pull the clutch lever in and use the brakes to stop the motorcycle Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on OPERATION AND IMPORTANT RIDING POINTS EAU02974 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Deceleration shift point km h mi h Acceleration shift point km h mi h 16 10 0 20 12 5 EAU01128 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 600 km 1 000 mi For this reason you should read the following material carefully Since the engine is brand new do not put an excessive load on it for the first 1 600 km 1 000 mi The various parts in the engine wear and polish them selves to the correct operating clear ances During this period prolonged full throttle operation or any condition that might result in engine overheating must be avoided 5 5 EAU04032 0 1 000 km 0 600 mi Avoid prolonged operation 4 500 r min above 1 000 1 600 km 600 1 000 mi Avoid prolonged operation 5 500 r min above EC000056 CAUTION After 1 000 km 600 mi of opera
32. anceling system the turn signal lights will self cancel after the motor cycle has traveled both about 150 m 490 ft and for approximately 15 sec onds However the turn signal lights can also be canceled manually by pushing the switch in after it has re turned to the center position NOTE The self canceling system only oper ates when the motorcycle is moving so that the turn signal lights will not self cancel while you are stopped at an in tersection EAU00130 Horn switch HORN Press this switch to sound the horn INSTRUMENT AND CONTROL FUNCTIONS 1 Engine stop switch ENGINE STOP 2 Fuel reserve switch FUEL 3 Start switch START EAU04822 Engine stop switch ENGINE STOP Set this switch to RUN before starting the engine Set this switch to OFF to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck 3 4 EAUO1653 Fuel reserve switch FUEL During normal operation this switch should be kept in the ON position If the fuel warning light comes on while riding set the switch to RES refuel as Soon as possible and then set the switch back to ON NOTE After switching to RES approximately 3 L 0 7 Imp gal 0 8 US gal of fuel re main in the fuel tank EAUO0141 Start switch START Push this switch to crank the engine
33. ant reservoir 14 Front brake fluid reservoir 15 Main switch 16 Radiator cap 17 Radiator 18 Engine oil filter cartridge 19 Engine oil level check window 20 Brake pedal 21 Rear brake fluid reservoir 2 2 page 3 6 page 6 35 page 6 16 page 6 29 page 3 1 page 6 18 page 6 18 page 6 13 page 6 12 page 3 6 page 6 29 DESCRIPTION DESCRIPTION Controls and instruments 1 Clutch lever 2 Left handlebar switches 3 Speedometer unit 4 Right handlebar switches 5 Brake lever 6 Throttle grip 7 Tachometer 8 Coolant temperature gauge 2 3 Main switch Indicator and warning lights Speedometer unit Tachometer Coolant temperature gauge Handlebar switches Clutch lever Shift pedal Brake lever Brake pedal Fuel tank cap Starter choke lever Steering lock Rider seat Helmet holder Adjusting the front fork Adjusting the shock absorber assemblies Matching the front and rear suspension settings V Boost Sidestand Ignition circuit cut off system INSTRUMENT AND CONTROL FUNCTIONS EAU00028 Main switch The main switch controls the ignition and lighting systems The various main switch positions are described below EAU00032 ON All electrical systems are supplied with power and the headlight meter light ing taillight and position lights come on and the engine can be started The key cannot be removed EAU00038 OFF All electrica
34. ark plug electrodes while turning the engine over MOTORCYCLE CARE AND STORAGE 6 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand centerstand Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlets with plas tic bags to prevent moisture from entering them Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than O C 30 F or more than 30 C 90 F For more informa tion on storing the battery see page 6 38 NOTE Make any necessary repairs before storing the motorcycle 7 5 Specifications SPECIFICATIONS Specifications Model Dimensions Overall length Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius Basic weight with oil and full fuel tank VMX12 VMX12C Engine Engine type Cylinder arrangement Displacement Bore x stroke Compression ratio Starting system Lubrication system VMX12 VMX12C 2 8300 mm 90 6 in 795 mm 31 3 in 1 160 mm 45 7 in 765 mm 30 1 in 1 590 mm 62 6 in 145 mm 5 7 in 2 900 mm 114 2 in 28
35. cartridge replace and drain bolt to drain the oil from 3 Wait a few minutes until the oil set ment the crankcase tles and then check the oil level through the check window located at the bottom right side of the 1 Start the engine warm it up for several minutes and then turn it NOTE Skip steps 4 6 if the oil filter cartridge is off crankcase 2 Place an oil pan under the engine non being replaced NOTE to collect the used oil The engine oil should be between the minimum and maximum level marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level 6 12 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Oil filter cartridge 1 O ring 1 Torque wrench 2 Oil filt h T AC UAE 5 Apply a thin coat of engine oil to 6 Install the new oil filter cartridge 4 Remove the oil filter cartridge with the O ring of the new oil filter car with an oil filter wrench and then an oil filter wrench tridge tighten it to the specified torque NOTE NOTE with a torque wrench An oil filler wrench is available at a Make sure that the O ring is properly RE Yamaha dealer seated ightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft Ibf 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 43 Nm 4 3 m k
36. checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore a Wear a brightly colored jacket b Use extra caution when you are approaching and passing through intersections since intersec tions are the most likely places for motorcycle accidents to occur c Ride where other motorists can see you Avoid riding in another motorist s blind spot N SAFETY INFORMATION Many accidents involve inexperienced operators In fact many operators who have been involved in accidents do not even have a current motorcycle license a Make sure that you are qualified and that you only lend your motorcycle to other qualified opera tors b Know your skills and limits Staying within your limits may help you to avoid an accident c We recommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with the motorcycle and all of its controls Many accidents have been caused by error of the motorcycle operator A typical error made by the operator is veering wide on a turn due to EXCESSIV
37. clearance Check and adjust valve clearance when engine is cold Every 30 000 mi 42 000 km or 42 months Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary Fuel line Check fuel hoses for cracks or damage Replace if necessary Fuel filter Replace every 20 000 mi 31 000 km or 30 months Replace Exhaust system Check for leakage Tighten if necessary Replace gasket s if necessary Carburetor synchronization Adjust synchronization of carburetors Idle speed Check and adjust engine idle speed Adjust cable free play 6 3 PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS ROUTINE INITIAL 600 mi 1 000 km or 1 month 4 000mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months Evaporative emission control system For California only Check control system for damage Replace if necessary Since these items require special tools data and technical skills have a Yamaha dealer perform the service 6 4 PERIODIC MAINTENANCE AND MINOR REPAIR Ge
38. de with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control and possibly an accident EW000030 INSTRUMENT AND CONTROL FUNCTIONS EAU03414 Adjusting the front fork This front fork is equipped with air valves for adjusting the spring rate Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result EW000035 1 Air valve cap 2 Air valve Adjust the spring rate as follows 1 Elevate the front wheel by placing the motorcycle on the centerstand NOTE When checking and adjusting the air pressure there should be no weight on the front end of the motorcycle 2 Remove the air valve cap from each fork leg 3 11 1 Air pressure gauge 3 Check the air pressure in each fork leg with an air pressure gauge NOTE An optional air pressure gauge is avail able at a Yamaha dealer 4 To increase the spring rate and thereby harden the suspension increase the air pressure with an air pump or compressed air To decrease the spring rate and thereby soften the suspension de crease the air pressure by pushing each valve stem down Spring rate Minimum standard soft Air pressure 40 kPa 0 4 kgf cm 5 7 psi Maximum hard Air pressure 100 kPa 1 0 kgf cm 14 psi EC000012 CAUTION Never exceed the maximum air pres sure otherwise the front fork oil seals may become damaged There must be n
39. e High quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Coolant quantity Total amount 3 05 L 2 68 Imp qt 3 22 US qt Coolant reservoir capacity up to the maximum level mark 0 3 L 0 26 Imp qt 0 32 US qt EC000080 CAUTION e If coolant is not available use distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine e If water has been used instead of coolant replace it with cool ant as soon as possible other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion PERIODIC MAINTENANCE AND MINOR REPAIR e If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced Install the radiator cap start the engine let it idle for several min utes and then turn it off Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap Start the engine and then check the vehicle for coolant leakage If coolant is leaking have a Yamaha d
40. e brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease 6 31 PERIODIC MAINTENANCE AND MINOR REPAIR Recommended lubricant Lithium soap based grease all purpose grease EAUOS3164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride and the lever pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease EAU03371 Checking and lubricating the centerstand and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it EW000114 6 32 PERIODIC MAINTENANCE AND MINOR REPAIR EAU04282 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lithium soap based grease EAU02939 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic main tenance and lubrication chart
41. e sure that all nuts bolts and screws are properly tightened Tighten if necessary Instruments lights signals and switches Check operation Correct if necessary Sidestand switch Check operation of ignition circuit cut off system f system is defective have Yamaha dealer check vehicle Battery Check fluid level Fill with distilled water if necessary PRE OPERATION CHECKS NOTE Pre operation checks should be made each time the motorcycle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle EWA00033 4 3 Starting and warming up a cold engine Starting a warm engine Shifting Engine break in Parking EAU00373 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or function that you do not thoroughly un derstand Never start the engine or oper ate it in a closed area for any length of time Exhaust fumes are poisonous and inhaling them can cause loss of con sciousness and death within a short time Always make sure that there is adequate ventila tion Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely
42. e the motorcycle off the cen terstand so that the front wheel is on the ground 7 Tighten the wheel axle then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques Tightening torques Wheel axle 58 Nm 5 8 m kgf 42 ft lbf Front wheel axle pinch bolt 20 Nm 2 0 m kof 14 ft Ibf Brake caliper bolt 40 Nm 4 0 m kgf 29 ft Ibf 8 Connect the speedometer cable 6 43 9 Push down hard on the handlebar Several times to check for proper fork operation PERIODIC MAINTENANCE AND MINOR REPAIR 1 Axle nut 1 Rear wheel axle pinch bolt R fai AVAST 1 Remove the axle nut and then Bad loosen the rear wheel axle pinch bolt To remove the rear wheel 2 Place the motorcycle on the cen Ewo000122 A WARNING terstand e Itis advisable to have a Yamaha dealer service the wheel e Securely support the motor cycle so that there is no danger of it falling over 6 44 Oahwnh Nut Cotter pin Brake torque rod Bolt x 3 Spacer Brake caliper bracket 3 4 Remove the brake caliper by re moving the bolts Disconnect the brake torque rod from the brake caliper bracket by removing the cotter pin the nut and the bolt PERIODIC MAINTENANCE AND MINOR REPAIR 5 EH While supporting the rear wheel pull the wheel axle out Remove the brake caliper bracket and spacer Pull the wheel to the right to sepa rate it from the final gear case and
43. ealer check the cooling system Install the cowling and the panel 6 20 PERIODIC MAINTENANCE AND MINOR REPAIR EC000082 CAUTION e Make sure that the air filter ele ment is properly seated in the air filter case e The engine should never be op erated without the air filter ele ment installed otherwise the pistons and or cylinders may 1 Screw x 6 1 Air filter element z become excessively worn g n RAUDE 3 Pull the air filter element out E TNT REIN eee a a Cleaning the air filter element 4 Lightly tap the air filter element to 6 Ma bed case CONSU Dy The air filter element should be cleaned remove most of the dust and dirt stalling the sc ews at the intervals specified in the periodic 7 Install the cowling and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it Insert the air filter element into the air filter case maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 5 1 Remove cowling A See page 6 8 for cowling removal and installa tion procedures 2 Remove the air filter case cover by removing the screws 6 21 EAU00628 Adjusting the carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore all carburetor adjustments should be left to a Yama
44. edal should be po the hydraulic system will dimin Sitioned approximately 20 mm 0 8 in ish the braking performance below the top of the footrest as shown which may result in loss of con Periodically check the brake pedal posi trol and an accident tion and if necessary have a Yamaha dealer adjust it play The brake lever free play should mea sure 2 5 mm 0 08 0 20 in as shown Periodically check the brake lever free play and if necessary adjust it as fol lows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rection To decrease the brake lever free play turn the adjusting bolt in direction 6 27 EW000109 A soft or spongy feeling in the brake pedal can indicate the presence of air in the hydraulic system If there is air in the hydraulic system have a Yamaha dealer bleed the system be fore operating the motorcycle Air in the hydraulic system will diminish the braking performance which may result in loss of control and an accident 1 Rear brake light switch 2 Rear brake light switch adjusting nut EAU00713 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in
45. ein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corp U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts oao SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects
46. extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on 1 Main fuse 1 Headlight fuse the electrical circuit in question to 2 Spare main fuse 2 Signaling system fuse check if the device operates g EAU01664 Ae iise 4 If the fuse immediately blows Replacing the fuses 5 Spare fuse x 2 again have a Yamaha dealer The main fuse box is located under the check the electrical system rider seat See page 3 9 for rider seat Specified fuses removal and installation procedures Main fuse The fuse box which contains the fuses Headlight fuse for the individual circuits is located un Signaling system fuse der cowling A See page 6 8 for cowl Radiator fan fuse ing removal and installation proce Ignition fuse dures If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 6 39 1 Screw x 2 EAU04187 Replacing the headlight bulb This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover PERIODIC MAINTENANCE AND MINOR REPAIR 1 Headlight bulb holder 3 Remove the headlight bulb ho
47. f the wind shield to make sure that it does not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning 7 2 After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on roads during winter are extremely corrosive in combination with water carry out the following steps after each ride in the rain near the sea or on salt sprayed roads NOTE Salt sprayed on roads in the winter may remain well into spring 1 Clean the motorcycle with cold water and a mild detergent after the engine has cooled down ECA00012 CAUTION Do not use warm waiter since it in creases the corrosive action of the salt 2 After drying the motorcycle apply a corrosion protection spray on all metal including chrome and nick el plated surfaces to prevent cor rosion MOTORCYCLE CARE AND STORAGE After cleaning Dry the motorcycle with a chamois A WARNING 1 2 or an absorbing cloth Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust System Even the thermally in
48. factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and loss of power The following troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferior have a shorter service life and can lead to expensive repair bills 6 46 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03363 Troubleshooting charts Starting problems or poor engine performance Keep away open flames and do not smoke while checking or working on the fuel system EWO000125 1 Fuel r There is enough fuel Check the compression Check the fuel level in the fuel tank Th TE VENT r e engine does not start There is no fuel Supply fuel gt Check the compressoin 2 Compression There is compression Check the ignition Operate the electric starter Have a Yamaha dealer check the vehicle There is no compression 3 Ignition Wipe off with a dry cloth and correct t
49. gf 31 ft lbf 6 13 PERIODIC MAINTENANCE AND MINOR REPAIR ECA00133 EC000067 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler CAUTION _ _ o If the oil level warning light flickers CAUTION e In order to prevent clutch slip cap Recommended engine oil See page 8 1 Oil quantity Without oil filter cartridge replacement 3 2 L 2 82 Imp qt 3 38 US qt With oil filter cartridge replacement 3 4 L 2 99 Imp qt 3 59 US qt page since the engine oil also lubricates the clutch do not mix any chemical additives Do not use oils with a diesel speci fication of CD or oils of a higher quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase or remains on immediately turn the engine off and have a Yamaha deal er check the vehicle 10 Turn the engine off and then check the oil level and correct it if necessary Total amount dry engine 9 Start the engine and then let it idle 4 L 3 52 Imp qt 4 23 US qt for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient 6 14 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03681 Final gear
50. h spark plug bore dry place and if necessary protect it Care section of this chapter c Install the spark plug caps onto against dust with a porous cover 2 For motorcycles equipped with a the spark plugs and then place ECA00014 fuel cock that has an OFF posi the spark plugs on the cylinder CAUTION tion Turn the fuel cock lever to head so that the electrodes are e Storing the motorcycle in a OFP grounded This will limit spark poorly ventilated room or cover Drain the carburetor float cham ing during the next step ing it with a tarp while it is still bers by loosening the drain bolts d Turn the engine over several wet will allow water and humid this will prevent fuel deposits from times with the starter This will ity to seep in and cause rust building up Pour the drained fuel coat the cylinder walls with oil into the fuel tank e Remove the spark plug caps e To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro tect the cylinders piston rings etc from corrosion 7 4 from the spark plugs and then install the spark plugs and the spark plug caps EWA00003 To prevent damage or injury from sparking make sure to ground the sp
51. ha dealer who has the neces sary professional knowledge and expe rience PERIODIC MAINTENANCE AND MINOR REPAIR a Throttle cable free play EAU00635 Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it 6 22 EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart PERIODIC MAINTENANCE AND MINOR REPAIR EAU03360 Tires To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride e The tire air pressure must be checked and adjusted on cold tires i e when the temperature of the tires equals the ambient temperature e The tire air pressure must be adjusted in accordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model EWo000082 Tire air pressure measured on cold tires Load Front Rear Up to 90 kg 198 Ib 225 kPa 2 2
52. he Open the throttle halfway and operate spark plug gaps or replace the spark plugs the electric starter p 1 Remove the spark plugs and check the electrodes The engine does not start Dry I Have a Yamaha dealer check the vehicle Check the battery 4 Battery MA E tums over The battery is good The engine does not start Operate the electric starter E I Have a Yamaha dealer The engine turns over Check the electrolyte and battery check the vehicle slowly lead connections and charge the battery if necessary 6 47 PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating e Do not remove the radiator cap when the engine and radiator are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury Be sure to wait until the engine has cooled e After removing the radiator cap retaining bolt place a thick rag like a towel over the radiator cap and then slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape When the hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap EW000070 There is Have a Yamaha dealer check The coolant level is low leakage and repair the cooling system C
53. he throttle See page 3 8 for starter choke opera tion 4 Start the engine by pushing the start switch OPERATION AND IMPORTANT RIDING POINTS NOTE If the engine fails to start release the start switch wait a few seconds and then try again Each starting attempt should be as short as possible to pre serve the battery Do not crank the en gine more than 10 seconds on any one attempt EC000038 CAUTION e The oil level warning light and fuel level warning light should come on when the start switch is pushed and they should go off when the start switch is re leased e Ifthe oil level warning light flick ers or remains on after starting immediately stop the engine and then check the engine oil level and the vehicle for oil leak age If necessary add engine oil and then check the warning light again If the warning light does not come on when push ing the start switch or if it does 5 2 not go off after starting with suf ficient engine oil have a Yamaha dealer check the elec trical circuit e If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come on when pushing the start Switch or if it does not go off af ter starting with sufficient fuel have a Yamaha dealer check the electrical circuit 5 After starting the engi
54. heck the cooling system for leakage There is Wait until the Check the coolant level in the no leakage Add coolant See NOTE engine has cooled reservoir and radiator The coolant level Start the engine If the engine overheats again have a is OK Yamaha dealer check and repair the cooling system NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible 6 48 Storage MOTORCYCLE CARE AND STORAGE Care While the open design of a motorcycle reveals the attractiveness of the tech nology it also makes it more vulnera ble Rust and corrosion can develop even if high quality components are used A rusty exhaust pipe may go un noticed on a car however it detracts from the overall appearance of a motorcycle Frequent and proper care does not only comply with the terms of the warranty but it will also keep your motorcycle looking good extend its life and optimize its performance Before cleaning 1 Cover the muffler outlets with plas tic bags after the engine has cooled down Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Alway
55. hs 20 000 mi 31 000 km or 30 months Control and meter cables Apply chain lube thoroughly Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE Ni y 4 Swingarm pivot bearing Check bearing assembly for looseness Moderately repack every 16 000 mi 25 000 km or 24 months Lithium soap based grease Brake and clutch lever pivot shaft Apply lithium soap based grease all purpose grease lightly Lithium soap based grease all purpose grease Brake pedal and shift pedal shaft Lubricate Apply lithium soap based grease all purpose grease lightly Lithium soap based grease all purpose grease Center sidestand pivots Check operation and lubricate Apply lithium soap based grease all purpose grease lightly Lithium soap based grease all purpose grease Front fork Check operation and leakage Steering bearings Check bearing assembly for looseness Moderately repack every 16 000 mi 25 000 km or 24 months Lithium soap based grease 6 6 PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 600 mi 4 000 mi 8 000 mi 12 000 mi 16 000 mi 20 000 mi ROUTINE 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km or or or or or 6 months 12 months 18 months 24 months 30 months Check bearings for J 4 NI
56. if necessary Check fluid level in reservoir f necessary add recommended brake fluid to specified level Check hydraulic system for leakage Check operation f soft or spongy have Yamaha dealer bleed hydraulic system Rear brake Check fluid level in reservoir f necessary add recommended brake fluid to specified level Check hydraulic system for leakage PRE OPERATION CHECKS CHECKS Clutch Check operation f soft or spongy have Yamaha dealer bleed hydraulic system Check fluid level in reservoir f necessary add recommended fluid to specified level Check hydraulic system for leakage 6 26 6 29 6 30 Throttle grip Make sure that operation is smooth Check cable free play f necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing 6 22 6 31 Control cables Make sure that operation is smooth Lubricate if necessary Wheels and tires Check for damage Check tire condition and tread depth Check air pressure Correct if necessary Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary Chassis fasteners Mak
57. ipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 9 4 CONSUMER INFORMATION EAU01874 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty The chart below is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 mi 37 000 km or 36 months 9 5 CONSUMER INFORMATION Maintenance Date of F Servicing dealer Mileage x Remarks interval service 28 000 mi 43 000 km or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months name and address CONSUMER INFORMATION YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants each new model Yamaha motorcycle will be free from defects in material and workmanship for the period of time stated her
58. it could contact the ground and distract the opera tor resulting in a possible loss of control OPERATION AND IMPORTANT RIDING POINTS EAU00376 CAUTION e Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result 5 1 EAU00372 EAU04700 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting one of the following conditions must be met e The transmission is in the neutral position e The transmission is in gear with the clutch lever pulled and the sidestand up EWO000054 e Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 18 Never ride with the sidestand down Turn the key to ON and make sure that the engine stop switch is set to RUN EC000035 CAUTION If the fuel level warning light comes on check the fuel level and if nec essary refuel as soon as possible 2 Shift the transmission into the neu tral position NOTE When the transmission is in the neutral position the neutral indicator light should be on otherwise have a Yamaha dealer check the electrical cir cuit 3 Turn the starter choke on and completely close t
59. ive years whichever occurs first 280cc or over 30 000 km 18 641 miles or five years whichever occurs first YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MER CHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR COR PORATION U S A AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY IN CIDENTAL OR CONSEQUENTIAL DAMAGES INCLUD ING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 EAUO2918 po e gt OP PrP P gt gt WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damages and oil oil filters air filters spark plugs and brake shoes What are some examples of abnormal strain neglect or abuse These terms are general and ove
60. k 6 41 EAU04163 Front wheel To remove the front wheel e Itis advisable to have a Yamaha dealer service the wheel e Securely support the motor cycle so that there is no danger of it falling over EWo000122 1 Place the motorcycle on the cen terstand PERIODIC MAINTENANCE AND MINOR REPAIR 1 Speedometer cable 2 Bolt x 2 3 Front wheel axle pinch bolt 4 Wheel axle 2 Disconnect the speedometer ca ble from the front wheel 3 Remove the brake calipers by re moving the bolts ECA00047 CAUTION Do not pull the brake lever after the brake caliper has been removed otherwise the brake pads will be forced shut 4 Loosen the front wheel axle pinch bolt then the wheel axle 5 Pull the wheel axle out and then remove the wheel 6 42 EAU04360 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots PERIODIC MAINTENANCE AND MINOR REPAIR 1 Retainer 2 Lift the wheel up between the fork legs NOTE Make sure that the slot in the speedom eter gear unit fits over the retainer on the fork leg 3 Insert the wheel axle 4 Install the brake calipers by install ing the bolts NOTE Make sure that there is enough space between the brake pads before install ing the brake calipers onto the brake discs 5 Install the brake hose holders by installing the bolts 6 Tak
61. ke and clutch fluids at the intervals specified in the NOTE after the periodic maintenance and lubrication chart In addition have the oil seals of the brake and clutch master cylinders and cali pers as well as the brake and clutch hoses replaced at the intervals listed below or whenever they are damaged or leaking e Oil seals years e Brake and clutch hoses Replace every four years Replace every two 6 30 PERIODIC MAINTENANCE AND MINOR REPAIR EAU03297 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is damaged or does not move smoothly have a Yamaha dealer check or replace it Recommended lubricant Yamaha Chain and Cable Lube or engine oil SAE 10W 30 API SE EW000111 Damage to the outer housing of ca bles may result in internal rusting and cause interference with cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions PERIODIC MAINTENANCE AND MINOR REPAIR EAU04034 Checking and lubricating the throttle grip and cable The operation of the throttle grip should be checked before each ride In addi tion the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU03370 Checking and lubricating the brake and shift pedals The operation of th
62. l is cracked con tact a Yamaha dealer immediately and have the tire replaced PERIODIC MAINTENANCE AND MINOR REPAIR FRONT Manufacturer Size Model Bridgestone 110 90 18 M C 61V 110 90 18 61V G525AW 110 90 18 M C 61V Dunlop F20 110 90 18 61V REAR Manufacturer Size Model Bridgestone 150 90 15 M C 74V G526BW Dunlop 150 90 15 M C 74V K525 Minimum tire tread depth front and rear 6 24 1 0 mm 0 04 in EAUO0684 This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires e Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds e Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi after installing a new tire e The tires must be warmed up before a high speed run e Always adjust the tire air pres sure according to the operating conditions PERIODIC MAINTENANCE AND MINOR REPAIR EAU00689 Cast wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels e The wheel rims should be checked for cracks bends warpage or damage before each ride If any damage is fou
63. l marks 4 If the coolant is at or below the minimum level mark remove the coolant reservoir cap and add coolant to the maximum level mark Install the coolant reservoir cap and the cowling 6 16 PERIODIC MAINTENANCE AND MINOR REPAIR EC000080 N OTE EAUO4865 CAUTION e The radiator fan is automatically To change the coolant e If coolant is not available use switched on or off according tothe Place the motorcycle on the cen distilled water or soft tap water coolant temperature in the radia terstand and let the engine cool if instead Do not use hard water tor necessary or salt water since it is harmful If the engine overheats see 2 Remove cowling A and panel A to the engine page 6 48 for further instructions See pages 6 8 and 6 9 for cowl ing and panel removal and instal lation procedures 3 Place a container under the en gine to collect the used coolant e If water has been used instead of coolant replace it with cool ant as soon as possible other wise the engine may not be sufficiently cooled and the cool ing system will not be protected against frost and corrosion 6 e If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced Never attempt to remove the radia tor cap when the engine is hot EWO000067 6 17 PERIODIC MAINTENANCE AND MI
64. l systems are off The key can be removed 1 Push 2 Release 3 Turn EAU00051 P Parking The meter lighting taillight and position lights are on but all other electrical sys tems are off The key can be removed The key must be pushed in from the OFF position to be turned to P ECA00043 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge 3 1 EAU00027 1 Neutral indicator light NEUTRAL 2 Turn signal indicator light TURN 3 Fuel level warning light FUEL 4 High beam indicator light HIGH BEAM 5 Oil level warning light OIL LEVEL EAU03034 Indicator and warning lights EAU00062 Neutral indicator light NEUTRAL This indicator light comes on when the transmission is in the neutral position EAUO0059 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left or right EAU04166 Fuel level warning light FUEL This warning light comes on when the fuel level drops below approximately 3 L 0 7 Imp gal 0 8 US gal When this occurs set the fuel reserve switch to the RES position and refuel as soon as possible The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to RUN and turn the key to ON 2 Shift the transmission into the neu tral position or p
65. lder by turning it counterclockwise and then remove the defective bulb EWO000119 A WARNING Headlight bulbs get very hot There fore keep flammable products away from a lit headlight bulb and do not touch the bulb until it has cooled down 4 Place a new headlight bulb into position and then secure it with the bulb holder 6 40 1 Do not touch the glass part of the bulb EC000105 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight bulb using a cloth moistened with alcohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headlight beam if necessary PERIODIC MAINTENANCE AND MINOR REPAIR 1 Screw x 2 1 Tail brake light bulb x 2 1 Turn signal light bulb Replaci t Hi ht 2 Remove the defective bulb by 4 Install the lens by installing the ep iacing a em Signa Ig pushing it in and turning it counter Screws bulb or the tail brake light clockwise EC000108 bulb 3 Insert a new bulb into the socket CAUTION 1 Remove the lens by removing the push it in and then turn it clock Do not overtighten the screws oth Screws wise until it stops erwise the lens may brea
66. m 2 3 m kgf 17 ft lbf 4 Add the recommended final gear oil to the brim of the filler hole Recommended final gear oil Hypoid gear oil SAE 80 API GL4 or multi grade hypoid gear oil SAE 80W 90 Oil quantity 0 2 L 0 18 Imp qt 0 21 US qt NOTE GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used 5 Install and tighten the filler bolt 6 Check the final gear case for oil leakage If oil is leaking check for the cause EAU04868 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic maintenance and lubrication chart To check the coolant level 1 NOTE Place the motorcycle on the cen terstand and hold it in an upright position Remove cowling A See page 6 8 for cowling removal and installa tion procedures e The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading PERIODIC MAINTENANCE AND MINOR REPAIR Coolant reservoir capacity up to the maximum level mark 0 3 L 0 26 Imp 0 32 US qt 1 Maximum level mark 2 Minimum level mark 3 NOTE Check the coolant level in the coolant reservoir The coolant should be between the minimum and maximum leve
67. med with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer Pre operation check list PRE OPERATION CHECKS aaa The condition of a vehicle is the owner s responsibility Vital components can start to deteriorate quickly and unexpectedly even if the vehicle remains unused for example as a result of exposure to the elements Any damage fluid leakage or loss of tire air pressure could have serious consequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride EAU03439 Pre operation check list CHECKS Check fuel level in fuel tank Refuel if necessary Check fuel line for leakage Check oil level in engine Engine oil f necessary add recommended oil to specified level Check vehicle for oil leakage Final gear oil Check vehicle for oil leakage Check coolant level in reservoir Coolant f necessary add recommended coolant to specified level Check cooling system for leakage Check operation f soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Front brake Adjust
68. nd have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel A deformed or cracked wheel must be replaced E e Ihe wheel should be balanced whenever either the tire or wheel has been changed or replaced An unbalanced wheel can result in poor performance adverse han dling characteristics and a short ened tire life e Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics e After repairing or replacing a tire tighten the valve stem nut and locknut to the specified torques Tightening torques Valve stem nut 1 6 Nm 0 16 m kgf 1 2 ft lbf Valve stem locknut 1 6 Nm 0 16 m kgf 1 2 ft Ibf 6 25 EAUO0691 Accessories and replacement parts This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically for this model and they must be securely mounted to main tain the inherent stability of the orig inal design Genuine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot con trol the quality of accessorie
69. ne move the starter choke back halfway ECA00055 CAUTION For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold OPERATION AND IMPORTANT RIDING POINTS 6 When the engine is warm turn the starter choke off NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off To avoid the possi bility of excessive exhaust emissions never leave the starter choke on long er than necessary The time necessary for starter choke use depends upon the ambient temperature Tempera tures above 10 C 50 F require about 7 seconds of starter choke use and temperatures below 10 C 50 F re quire about 35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm 5 3 IAL Y a o A 4 3 t2 Hill O 07 Be 7 p 1 Shift pedal N Neutral position EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off accelerating climbing hills etc The gear positions are shown in the il lustration NOTE To shift the transmission into the neu tral position press the shift pedal down re
70. neral maintenance and lubrication chart ROUTINE INITIAL ODOMETER READINGS EAU00472 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 12 000 mi 13 000 km 19 000 km or or 12 months 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months Engine oil Replace warm up engine before draining See page 8 1 Ni Engine oil filter cartridge Replace Air filter element Clean with compressed air Replace if necessary Cooling system Check hose for cracks or damage replace if necessary Replace every 16 000 mi 25 000 km or 24 months High quality ethylene glycol antifreeze containg corrosin inhibitors for aluminum engine Replace Brake system Adjust free play Replace pads if necessary Clutch Check operation and fluid leakage See NOTE page 6 7 Correct if necessary Final gear oil Check oil level and leakage Replace every 16 000 mi 25 000 km or 24 months Hypoid gear oil SAE 80 API GL 4 Replace 6 5 Replace ROUTINE PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ODOMETER READINGS 600 mi 1 000 km 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 000 mi 19 000 km or 12 months 18 months 16 000 mi 25 000 km or 24 mont
71. ng the sidestand switch clutch switch and neutral switch has the fol lowing functions e It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled e It prevents starting when the trans mission is in gear and the clutch lever is pulled but the sidestand is still down e It cuts the running engine when the transmission is in gear and the sidestand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure e The vehicle must be placed on the centerstand during this in spection e If a malfunction is noted have a Yamaha dealer check the sys tem before riding EW000046 INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off 1 Move the sidestand down 2 Make sure that the engine stop switch is set to RUN 3 Turn the key to ON 4 Shift the transmission into the neutral position 5 Push the start switch Does the engine start With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The system is OK The motorcycle can be ridden 3 18 NOTE This check is most reliable if perfor
72. ning the air filter element 6 21 Adjusting the carburetors sssess 6 22 Adjusting the throttle cable free play 6 22 Adjusting the valve clearance 6 22 MC amm 6 23 Cast Wheels crest te e eot tes 6 25 Accessories and replacement parts 6 25 Clutch lever free play scce 6 26 Adjusting the brake lever free play 6 27 Adjusting the brake pedal position 6 27 Adjusting the rear brake light switch 6 28 Checking the front and rear brake pads 6 28 Checking the brake and clutch fluid levels 6 29 Changing the brake and clutch fluids 6 30 Checking and lubricating the cables 6 30 Checking and lubricating the throttle grip and Cable itin abiere n REN 6 31 Checking and lubricating the brake and shift pedals 4 5 aee 6 31 Checking and lubricating the brake and clutch leVers sain lines regt uena 6 32 Checking and lubricating the centerstand and sidestand uxori Ea 6 32 Lubricating the rear suspension 6 33 Checking the front fork sssr 6 33 Checking the steering ssussessss 6 34 Checking the wheel bearings 6 35 BalterVis coco ente une 6 35 Replacing the fuses 6 39 Replacing the headlight bulb 6 40
73. nstalling Removing Wheel rear Installing Removing Wheels See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2002 05 0 9x1 CR E
74. nty requirements to your satis faction at the time of sale and upon your request at any later date 3 Each Yamaha Motorcycle dealer is held responsible for his setup service and warranty repair work Is the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha Motorcycle dealer for the policy to remain effective CONSUMER INFORMATION CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha Motorcycle dealer within the continental United States Be sure to bring your warranty registration card or other valid proof of the original date of purchase If a question or problem arises regarding warranty first con tact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model V I N frame number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers ag
75. o difference in air pressure between the left and right fork legs otherwise poor handling and loss of stability may result EWA00037 5 Securely install the air valve caps INSTRUMENT AND CONTROL FUNCTIONS 1 Shock absorber assembly x 2 EAU01657 Adjusting the shock absorber assemblies Both shock absorber assemblies are equipped with a spring preload adjust ing ring and a damping force adjusting knob EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 3 12 EW000040 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result INSTRUMENT AND CONTROL FUNCTIONS Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction 8 To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly in direction b NOTE e Align the bottom edge of the ad justing ring with the appropriate setting on the shock absorber Use the special wrench included in the owner s tool kit to make this adjustment Spring preload Minimum soft 1 Standard 1 Maximum hard 5 3 13 1 Damping force adjusting knob 2 Position indicator Damping force To increase the damping force and thereby harden the damping turn the adjusting kn
76. ob on each shock absorber assembly in direction To decrease the damping force and thereby soften the damping turn the adjusting knob on each shock absorber assembly in direction NOTE Align the appropriate setting on the ad justing knob with the position indicator on the shock absorber INSTRUMENT AND CONTROL FUNCTIONS Damping force Minimum soft 1 Standard 1 Maximum hard 4 INSTRUMENT AND CONTROL FUNCTIONS EAU01658 Matching the front and rear suspension settings Use this table as a guide to match the suspension and damping adjustments of the front fork and shock absorber assembly according to various load conditions Load condition Front fork adjustment Shock absorber assembly adjustment Spring preload air pressure Spring preload Damping force 40 60 kPa Rider only 0 4 0 6 kgf cm 1 2 1 2 5 7 8 5 psi 40 100 kPa 0 4 1 0 kgf cm 5 7 14 psi 40 100 kPa 0 4 1 0 kgf cm 5 7 14 psi With passenger or with accessories and equipment With passenger accessories and equipment EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 3 15 EAU00327 V Boost The V Boost is a vital part of the engine and requires very sophisticated adjust ment Adjustment should be left to a Yamaha dealer who has the profes sional knowledge and experience to do so ECO000025 CAUTION The V Boost was se
77. of fuel This information will en able you to plan future fuel stops INSTRUMENT AND CONTROL FUNCTIONS 1 Tachometer 2 Tachometer red zone EAU00101 Tachometer The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range EC000003 CAUTION Do not operate the engine in the tachometer red zone Red zone 8 500 r min and above 1 Coolant temperature gauge 2 Coolant temperature gauge red zone EAU01652 Coolant temperature gauge With the key in the ON position the coolant temperature gauge indicates the temperature of the coolant The coolant temperature varies with chang es in the weather and engine load If the needle reaches or enters the red zone stop the motorcycle and let the engine cool See page 6 48 for further instructions EC000002 CAUTION Do not operate the engine if it is overheated 3 3 1 Dimmer switch LIGHTS 2 Turn signal switch TURN 3 Horn switch HORN EAU00118 Handlebar switches EAU00122 Dimmer switch LIGHTS Set the switch to HI for the high beam and to LO for the low beam EAUO1189 Turn signal switch TURN To signal a right hand turn push this switch to the right To signal a left hand turn push the switch to the left When released the switch returns to the cen ter position Since this model is equipped with a self c
78. oil The final gear case must be checked for oil leakage before each ride If any leakage is found have a Yamaha deal er check and repair the motorcycle In addition the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart e Make sure that no foreign mate rial enters the final gear case e Make sure that no oil gets on the tire or wheel EW000066 To check the final gear oil level 1 Place the motorcycle on the cen terstand NOTE e The final gear oil level must be checked on a cold engine e Make sure that the motorcycle is positioned straight up when check ing the oil level A slight tilt to the side can result in a false reading 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil drain bolt 2 Remove the oil filler bolt and then check the oil level in the final gear case NOTE The oil level should be at the brim of the filler hole 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 6 15 2 Remove the oil filler bolt and drain bolt to drain the oil from the final gear case 3 Install the final gear oil drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 23 N
79. on in the spaces pro vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi cle is stolen 1 KEY IDENTIFICATION NUMBER MEM 2 VEHICLE IDENTIFICATION NUMBER NENNEN E 3 MODEL LABEL INFORMATION OQ C OO 1 Key identification number EAU01042 Key identification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key 9 1 EAU01039 1 Vehicle identification number EAUO1043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your motorcycle and may be used to register your motor cycle with the licensing authority in your area 1 Model label EAU03424 Model label The model label is affixed under cowl ing A See page 6 8 for cowling re moval and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 9 2 CONSUMER INFORMATION CONSUMER INFORMATION EAU01051 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death you should immedi ately inform the National Highway Traffic Safety Administration
80. peatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION e Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmission Always use the clutch while changing gears to avoid dam aging the engine transmission and drive train which are not designed to withstand the shock of forced shifting OPERATION AND IMPORTANT RIDING POINTS EAU02988 To start out and accelerate 1 2 NOTE Pull the clutch lever to disengage the clutch Shift the transmission into first gear The neutral indicator light should go out Open the throttle gradually and at the same time release the clutch lever slowly At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pull the clutch lever in Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion Open the throttle part way and gradually release the clutch lever Follow the same procedure when shifting to the next higher gear Always shift gears at the recommend ed shift points 5 4 EAU00427 To decelerate 1 2 Apply both the front and the rear br
81. r wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident 5 Never touch the engine or exhaust system during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications may also make your motorcycle illegal to use Loading and accessories Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use extreme caution when adding cargo or accessories to your motorcycle Use extra care when riding a motorcycle that has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding ac cessories to your motorcycle N SAFETY INFORMATION Loading The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of VMX12 476 Ib 216 kg VMX12C 474 Ib 215 kg When loading within this weight limit keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to di
82. rlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and or tie down If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover incidental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by Yamaha Motorcycle dealer Will the warranty be void or cancelled if do not operate or maintain my new motor cycle exactly as specified in the Owner s Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha Motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warra
83. s or parts manufactured by other com panies Yamaha cannot be held lia EW000098 ble for any consequences caused by the use of items which have not been approved by Yamaha PERIODIC MAINTENANCE AND MINOR REPAIR EAU00695 Clutch lever free play Since this model is equipped with a hy draulic clutch adjusting the clutch lever free play is not needed However it is necessary to check the clutch fluid lev el and check the hydraulic system for leakage before each ride If the clutch lever free play does become exces sive and shifting becomes rough or clutch slippage occurs causing poor acceleration there may be air in the clutch system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle 6 26 PERIODIC MAINTENANCE AND MINOR REPAIR 3 Tighten the locknut e After adjusting the brake lever free play check the free play and make sure that the brake is working properly e A soft or spongy feeling in the brake lever can indicate the EW000099 1 Locknut ae x a Distance between brake pedal and footrest 2 Brake lever free play adjusting bolt Sane in the a TNR c Brake lever free play system ere IS air in tne hy hunen draulic system have a Yamaha Adjusting the brake pedal Adjusting the brake lever free dealer bleed the system before POSition operating the motorcycle Air in The top of the brake p
84. s rinse the dirt and degreaser off with water 7 1 EAUO3412 Cleaning ECA00010 CAUTION e Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a corrosion protection spray e Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic e Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products solvent or thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte e Do not use high pressure wash ers or steam jet cleaners since they cause water seepage and deterioration in the following ar eas seals of wheel and swing arm bearings fork and brakes electric components couplers connectors instruments switch es and lights breather hoses and vents MOTORCYCLE CARE AND STORAGE e For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning compounds for plastic may leave scratches on the wind shield Test the product on a small hidden part o
85. stribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal ance or instability 2 Shifting weights can create a sudden imbalance Make sure that accessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebar front fork or front fender These items in cluding such cargo as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories Use extreme caution when select ing and installing any accessories Keep the following guidelines in mind as well as those provided under Loading when mounting acces sories 1 Never install accessories or carry cargo that would impair the performance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors 1 4 N SAFETY INFORMATION a Accessories fitted to the handlebar or the front fork area can create instability due to improper weight
86. t at the Yamaha factory after many tests If the set tings are changed by someone with out sufficient technical knowledge poor engine performance and dam age may result INSTRUMENT AND CONTROL FUNCTIONS The V Boost operation can be heard when the main switch is turned on EC000026 CAUTION If the V Boost does not operate ask a Yamaha dealer to inspect it 3 16 INSTRUMENT AND CONTROL FUNCTIONS EAU00330 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the motorcycle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system EW000044 The motorcycle must not be ridden with the sidestand down or if the sidestand cannot be properly moved up or does not stay up oth erwise the sidestand could contact the ground and distract the opera tor resulting in a possible loss of control Yamaha s ignition circuit cut off system has been designed to assist the operator in fulfilling the responsibility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly 3 17 EAU03741 Ignition circuit cut off system The ignition circuit cut off system com prisi
87. the cowling Removing and installing the 1 Insert the key into the lock and cowling and panels then turn it clockwise The cowling and panels shown above 2 Pull the cowling off as shown need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time the cowling or a panel needs to be removed and installed 6 8 PERIODIC MAINTENANCE AND MINOR REPAIR 1 Screw x 2 EAU03340 Panel A To remove the panel 1 Remove cowling A See page 6 8 for cowling removal and installa tion procedures Remove the screws and then take the panel off To install the panel 1 2 Place the panel in the original po sition and then install the screws Install the cowling 1 Screw x 2 EAU01315 Panel B To remove the panel Remove the screws and then take the panel off To install the panel Place the panel in the original position and then install the screws 6 9 1 Spark plug cap EAU03329 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the condition of the spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap PERIOD
88. the positive battery lead and the starter motor lead to the starter motor relay EWO000118 WARNING Pass the positive battery lead and starter lead through the hole in the ignition coil bracket as shown Im proper routing of these leads could bring about a short circuit causing the engine and lights to fail and pos sibly resulting in an accident 14 Connect and tighten the negative battery lead to the battery 15 Install the rider seat PERIODIC MAINTENANCE AND MINOR REPAIR To store the battery 1 If the motorcycle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place If the battery will be stored for more than two months check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever nec essary Fully charge the battery before in stallation After installation make sure that the battery leads are properly con nected to the battery terminals and that the breather hose is properly routed in good condition and not obstructed 6 38 EC000099 CAUTION If the breather hose is positioned in such a way that the frame is ex posed to electrolyte or gas expelled from the battery the frame could suffer structural and external dam ages PERIODIC MAINTENANCE AND MINOR REPAIR EC000103 CAUTION Do not use a fuse of a higher amper age rating than recommended to avoid causing
89. tion the engine oil and final gear oil must be changed and the oil filter car tridge replaced 1 600 km 1 000 mi and beyond The vehicle can now be operated nor mally EC000053 CAUTION _ _ _ _ o e Keep the engine speed out of the tachometer red zone e If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU00460 Parking When parking stop the engine and then remove the key from the main switch e Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them e Do not park on a slope or on soft ground otherwise the motorcycle may overturn EW000058 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance sees 6 1 Owner s tool kit isieseesseeeseieeriesrreerressrrnsrreess 6 1 Periodic maintenance chart for emission control system 6 3 General maintenance and lubrication chart 6 5 Removing and installing the cowling and panels iur beg id gasedisedpandets cede 6 8 Checking the spark plugs sesssss 6 9 Canister for California only 6 11 Engine oil and oil filter cartridge 6 11 Final gear oil oA a a a EARE AEREA 6 15 Goolant icc th E A 6 16 Clea
90. ull the clutch lever 3 Push the start switch If the warn ing light does not come on have a Yamaha dealer check the electri cal circuit EAU00064 High beam indicator light HIGH BEAM This indicator light comes on when the high beam of the headlight is switched on INSTRUMENT AND CONTROL FUNCTIONS EAU04167 Oil level warning light OIL LEVEL This warning light comes on when the engine oil level is low The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to RUN and turn the key to ON 2 Shift the transmission into the neu tral position or pull the clutch lever 3 Push the start switch If the warn ing light does not come on have a Yamaha dealer check the electri cal circuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function 3 2 1 Tripmeter reset knob 2 Odometer 3 Tripmeter EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odometer shows the total distance traveled The tripmeter shows the distance traveled since it was last set to zero with the reset knob The tripmeter can be used to estimate the distance that can be traveled with a full tank
91. ut and then release it 3 Remove the key and then close the lock cover 1 Steering lock 1 Lever x 2 EAU02934 EAU03413 Steering lock Rider seat To lock the steering To remove the rider seat 1 Turn the handlebar all the way to 1 Release the rider seat backrest by right 2 Open the steering lock cover and then insert the key 3 Turn the key 1 8 turn counter clockwise push it in while turning the handlebar slightly to the left and then turn the key 1 8 turn clockwise 4 Check that the steering is locked remove the key and then close the lock cover 3 9 pushing the levers on the left and right side as shown and then slide the backrest forward 1 Bolt x 2 2 Screw x 2 2 Remove the bolts and screws and then pull the rider seat off INSTRUMENT AND CONTROL FUNCTIONS 1 Projection 2 Seat holder To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown 2 Place the rider seat in the original position and then tighten the bolts and screws NOTE Make sure that the seat is properly se cured before riding 3 Return the rider seat backrest to the original position 3 10 1 Helmet holder 2 Unlock EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key Never ri
92. ways turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motorcycle note the following N SAFETY INFORMATION a The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not likely to touch these hot areas b Do not park the motorcycle on a slope or soft ground otherwise it may fall over c Do not park the motorcycle near a flammable source e g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the carburetor or fuel tank 5 f you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash the affected area with soap and water and change your clothes 1 6 N SAFETY INFORMATION EAUO2977 Location of important labels EI Please read the following important labels carefully before operating this motorcycle A SAFETY INFORMATION 4 California only WARNING BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS EMISSION HOSE ROUTING ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing 5GK 2118K 00 FROM
93. with the starter EC000005 CAUTION See page 5 1 for starting instruc tions prior to starting the engine INSTRUMENT AND CONTROL FUNCTIONS 1 Clutch lever EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 17 for an explanation of the ignition circuit cut off system 1 Shift pedal EAU00157 Shift pedal The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle 3 5 1 Brake lever EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip INSTRUMENT AND CONTROL FUNCTIONS 1 Brake pedal 1 Lever x 2 EAU00162 EAU04168 Brake pedal Fuel tank cap The brake pedal is on the right side of the motorcycle To apply the rear To remove the fuel tank cap brake press down on the brake pedal 1 Push the levers on the left and right side of the rider seat backrest as shown and slide
94. y x 2 2 Bolt x 2 3 Coupler x 4 7 8 9 Disconnect the couplers shown Remove the ignition coil assem blies by removing the bolts Add distilled water to raise the electrolyte to the maximum level mark PERIODIC MAINTENANCE AND MINOR REPAIR Ewo00116 e KEEP THIS AND ALL BATTER WARNING 8 IES OUT OF THE REACH OF e Electrolyte is poisonous and CHILDREN dangerous since it contains sul furic acid which causes severe CAUTION burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when EC000100 Use only distilled water as tap water contains minerals that are harmful to the battery working near batteries In case y of contact administer the fol Ee breather hoss lowing FIRST AID 3 Pass through the cable guide EXTERNAL Flush with plenty 10 Check and if necessary correct of water the breather hose routing 11 Install the ignition coil assemblies by installing the bolts 12 Connect the couplers INTERNAL Drink large quan tities of water or milk and im mediately call a physician EYES Flush with water for 15 minutes and seek prompt medical attention e Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space 6 37 1 Positive battery lead red 2 Starter motor lead black 13 Connect and tighten

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