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Yamaha AW4416 Stereo System User Manual

1. General maintenance and lubrication chart ROUTINE INITIAL PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS EAU32182 600 mi 1 month 4000 mi 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Air filter element e Clean with compressed air e Replace if necessary Ni Ni Ni Ni Battery e Check specific gravity and breath er hose for proper operation Ni Ni Clutch e Check operation and fluid leak age e Correct if necessary Front brake e Check operation fluid level and for fluid leakage e Replace brake pads if necessary Rear brake e Check operation fluid level and for fluid leakage e Replace brake pads if necessary Brake hoses e Check for cracks or damage Ni Ni e Replace Every 4 years Wheels e Check runout and for damage e Replace if necessary Ni Ni e Check tread depth and for dam age e Replace if necessary e Check air pressure e Correct if necessary ROUTINE INITIAL ODOMETER READINGS Be zxxrryxy _ _ EEE MAINTENANCE ANE MINOR RERAIR 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi
2. 4 1 Pre operation check list 4 2 OPERATION AND IMPORTANT RIDING POINTS eee 5 1 Starting and warming up a cold ONGING sit scene ria aiai 5 1 Starting a warm engine 5 3 SHINING e e araea aaa il 5 3 Engine break in eee 5 4 Parking nornin 5 5 PERIODIC MAINTENANCE AND MINOR REPAIR 6 1 PERIODIC MAINTENANCE 6 1 Owner s tool kit aaae 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication Chart eee 6 4 Removing and installing the cowling and panels eee 6 8 Checking the spark plugs 6 9 Canister for California only 6 10 Engine oil and oil filter cartridge 6 11 Final gear oil eenen 6 13 Coolant viii tatnctin diets 6 14 Cleaning the air filter element 6 18 Adjusting the carburetors 6 19 TABLE OF CONTENTS Adjusting the throttle cable free play eieiei diel ee eae 6 19 Adjusting the valve clearance 6 19 MrS aapea eoa aaa 6 20 Cast wheels asise 6 22 Accessories and replacement parE icicle 6 22 Clutch lever free play cee 6 23 Adjusting the brake lever free Play eienaar an 6 23 Adjusting the rear brake light SWITCH tesecciiedesctesstetsiasentdstisetece 6 24 Checking the front and rear brake pads cn 6 24 Checking the brake and Clutch fluid levels eee 6 25 Changing the brake and Clutch fluids n
3. 3 Turn the starter choke on and completely close the throttle See page 3 8 4 Start the engine by pushing the start switch 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 ECA10230 CAUTION _ o o 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 If the 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 not go off after starting with suf ficient engine oil have a Yamaha dealer check the elec trical circuit 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 OPERATION AND IMPORTANT RIDING POINTS ter starting with sufficient fuel have a Yamaha dealer check the electrical circuit
4. DESCRIPTION EAU10430 INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch The main switch controls the ignition and lighting systems The various main switch positions are described below EAU10510 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 EAU10660 OFF All electrical systems are off The key can be removed EAU10822 P Parking 1 Push 2 Turn 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 ECA11020 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge 3 1 EAU11001 Indicator and warning lights IS 1 Neutral indicator light NEUTRAL 2 Turn signal indicator light TURN 3 Fuel level warning light FUEL 4 5 High beam indicator light HIGH BEAM Oil level warning light OIL LEVEL EAU11040 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left or right EAU11070 Neutral indicator light NEUTRAL This indicator light comes on when the transmission is in the neutral position EAU11090 High beam indic
5. 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 en gine EWA10880 ECA10070 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU13300 Recommended fuel UNLEADED GASOLINE ONLY Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal ECA11400 CAUTION Use only unleaded gasoline The use of leaded gasoline will cause severe damage to internal engine parts such as the valves and piston rings as well as to the exhaust system 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 3 7 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 EAU Iseg0 F av18730 To unlock the steerin
6. 1 O ring 1 Torque wrench NOTE Tightening torque ring Oil filter cartridge oe that the O ring is properly 17 Nm 1 7 m kgf 12 ft lbf 6 Install the new oil filter cartridge 7 Install the engine oil drain bolt and with an oil filter wrench and then then tighten it to the specified tighten it to the specified torque torque with a torque wrench Tightening torque Engine oil drain bolt 43 Nm 4 3 m kgf 31 ft lbf 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 6 12 Recommended engine oil See page 8 1 Oil quantity Without oil filter cartridge replace ment 3 50 L 3 70 US qt 3 08 Imp qt With oil filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt ECA11620 CAUTION e In order to prevent clutch slip 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 high er 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 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately 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 sufficie
7. 6 26 Checking and lubricating the Cables iire hee 6 26 Checking and lubricating the throttle grip and cable 6 27 Checking and lubricating the brake and shift pedals 6 27 Checking and lubricating the brake and clutch levers 6 28 Checking and lubricating the centerstand and sidestand 6 28 Lubricating the rear suspension 6 28 Checking the front fork 0 6 29 Checking the steering 6 6 29 TABLE OF CONTENTS Checking the wheel bearings 6 30 Battery ceric ed eee 6 30 Replacing the fuses 6 33 Replacing the headlight bulb 6 34 Replacing a turn signal light bulb or the tail brake light bulb 6 35 Front wheel eeeceeeeeeeeeeeeeeees 6 36 Rear wheel ee eeeeseeeeseeeeeeeeeeee 6 37 Troubleshooting seee 6 39 Troubleshooting charts 6 40 MOTORCYCLE CARE AND STORAGE ce ieee 7 1 Cale ese ini ie le 7 1 SOAGE pie orient ean isa oiei EA 7 3 SPECIFICATIONS 0 000008 8 1 CONSUMER INFORMATION 9 1 Identification numbers c008 9 1 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record cccccccceeees 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY siseisicss cid Sysasiaativeat 9 7 YAMAHA EXTENDED SERVICE VY SS Dn N 9 9 A SAFETY INFORMATION
8. 9 Add distilled water to raise the electrolyte to the maximum level mark e Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near batteries In case of contact administer the fol lowing FIRST AID e EXTERNAL Flush with plenty of water EWA10760 PERIODIC MAINTENANCE AND MINOR REPAIR e INTERNAL Drink large quan tities of water or milk and im mediately call a physician e 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 e KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN ECA10610 CAUTION Use only distilled water as tap water contains minerals that are harmful to the battery 10 Check and if necessary correct the breather hose routing 1 Battery 2 Battery breather hose 3 Pass through the cable guide 11 Install the ignition coil assemblies by installing the bolts 12 Connect the couplers 13 Connect and tighten the positive battery lead and the starter motor lead to the starter motor relay EWA10780 A WARNING Pass the positive battery lead and starter lead through the hole in the ignition coil bracket as s
9. EAU11630 Speedometer unit 1 Tripmeter reset knob 2 Odometer 3 Tripmeter 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 of fuel This information will en able you to plan future fuel stops INSTRUMENT AND CONTROL FUNCTIONS EAU11851 Tachometer EAU12171 Coolant temperature gauge 1 Tachometer 2 Tachometer red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range ECA10031 CAUTION Do not operate the engine in the ta chometer red zone Red zone 9000 r min and above 1 Coolant temperature gauge 2 Coolant temperature gauge red zone 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 vehicle and let the en gine cool See page 6 40 ECA10020 CAUTION Do not operate the engine if it is overheated 3 3 EAU12343 Handlebar switches Left 1 Dimmer switch LIGHTS 2 Turn signal
10. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the side stand centerstand 7 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 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 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 0 C 30 F or more than 30 7 4 SPECIFICATIONS Dimensions Overall length 2300 mm 90 6 in Overall width 795 mm 31 3 in Overall height 1160 mm 45 7 in Seat height 765 mm 30 1 in Wheelbase 1590 mm 62 6 in Ground clearance 145 mm 5 71 in Minimum turning radius 2900 mm 114 2 in Weight With oil and fuel 283 0 kg 624 Ib U49 284 0 kg 626 Ib CAL ZAF Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement V type 4 cylinder Displacement 1198 0 cm 73 10 cu in Bore x stroke 76 0 x 66 0 mm 2 99 x 2 60 in Compression ratio 10 50 1 Starting system Electric starter Lubrication system Wet sump Engine oil Type SAE10W30 or SAE10W40 or SAE15W40 or SAE20W40 or SAE20W50 ZAF YAMALUBE 4 SAE10W30 or SAE20W
11. 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 EAU21980 Cast wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warpage or damage before each ride If any damage is found 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 The 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 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
12. Start switch START Push this switch to crank the engine with the starter ECA10050 CAUTION See page 5 1 for starting instruc tions prior to starting the engine EAU12790 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 3 4 NOTE After switching to RES approximately 3 0 L 0 79 US gal 0 66 Imp gal of fuel remain in the fuel tank INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever 1 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 14 EAU12870 Shift pedal x O 1 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 EAU12890 Brake lever 1 Brake lever The brake lever is located at the right handlebar grip To apply the fron
13. YAMAHA EAU10041 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 INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha VMX12 This model is the result of Yamaha s vast experience in the pro duction of fine sporting touring and pacesetting racing machines It represents the high degree of craftsmanship and reli ability 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 emissions 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 IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS A INVOLVED Failure to follo
14. in crease the air pressure with an air pump or compressed air To de crease the spring rate and thereby soften the suspension decrease the air pressure by pushing each valve stem down Spring rate Minimum standard soft Air pressure 40 kPa 5 7 psi 0 4 kgf cm Maximum hard Air pressure 100 kPa 14 psi 1 0 kgf cm ECA10090 CAUTION Never exceed the maximum air pres sure otherwise the front fork oil seals may become damaged There must be no difference in air pressure between the left and right fork legs otherwise poor handling and loss of stability may result EWA11180 5 Securely install the air valve caps EAU15081 Adjusting the shock absorber assemblies 1 Shock absorber assembly Both shock absorber assemblies are equipped with a spring preload adjust ing ring and a damping force adjusting knob ECA10100 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings 3 11 EWA10210 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in direction a 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
15. warm engine before draining Engine oil filter car tridge e Replace Cooling system e Check hoses for cracks or dam age e Replace if necessary e Change with ethylene glycol anti freeze coolant every 24 months Final gear oil e Check oil level and for oil leakage e Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Control and meter cables e Apply Yamaha chain and cable lube or engine oil 10W 30 thor oughly Throttle grip hous ing and cable e Check operation and free play e Adjust the throttle cable free play if necessary e Lubricate the throttle grip housing and cable 6 6 Since these items require special tools data and technical skills have a Yamaha dealer perform the service PERIODIC MAINTENANCE AND MINOR REPAIR NOTE From 24000 mi 37000 km or 36 months repeat the maintenance intervals starting from 8000 mi 13000 km or 12 months EAU17660 NOTE The air filter needs more frequent service if you are riding in unusually wet or dusty areas e Hydraulic brake and clutch systems e 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 e Replace the oil seals on the inner parts of the brake or clutch master cylinde
16. 1 2 Follow all the instructions in the Care section of this chapter For motorcycles equipped with a fuel cock that has an OFF posi tion Turn the fuel cock lever to OFP 7 3 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank 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 a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore c Install the spark plug caps onto the spark plugs and then place the spark plugs on the cylinder head so that the electrodes are grounded This will limit spark ing during the next step d Turn the engine over several times with the starter This will coat the cylinder walls with oil e Remove the spark plug caps from the spark plugs and then install the spark plugs and the spark plug caps MOTORCYCLE CARE AND STORAGE ATAA C 90 F For more information WARNING gt on storing the battery see page To prevent damage or injury from 6 30 sparking make sure to ground the NOTE spark plug electrodes while turning i the engine over Make any necessary repairs before storing the motorcycle 6
17. 31000 km or 30 months Wheel bearings e Check bearings for smooth oper ation e Replace if necessary Swingarm pivot bearings e Check bearing assemblies for looseness e Moderately repack with lithium soap based grease Steering bearings e Check bearing assemblies for looseness e Moderately repack with lithium soap based grease every 16000 mi 25000 km or 24 months Chassis fasteners e Check all chassis fitting and fas teners e Correct if necessary Brake and clutch le ver pivot shafts e Apply lithium soap based grease all purpose grease lightly Brake and shift ped al pivot shafts e Apply lithium soap based grease all purpose grease lightly Centerstand and sidestand pivots e Check operation e Apply lithium soap based grease all purpose grease lightly Sidestand switch e Check operation and replace if necessary Front fork e Check operation and for oil leak age e Replace if necessary ROUTINE INITIAL PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READINGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Shock absorber as semblies e Check operation and for oil leak age e Replace if necessary Engine oil e Change
18. 5 After starting the engine move the starter choke back halfway ECA11130 CAUTION For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 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 5 2 choke turned on then about 2 5 min utes with the starter choke in the half way position OPERATION AND IMPORTANT RIDING POINTS EAU16640 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 EAU16671 Shifting a Ye lai KAN 3 1f OK 42 4 O N O Se ye G 1 Shift pedal 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
19. 600 1000 mi Avoid prolonged operation above 5500 r min OPERATION AND IMPORTANT RIDING POINTS ECA10331 CAUTION After 1000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter car tridge or element replaced 1600 km 1000 mi and beyond The vehicle can now be operated nor mally ECA10310 CAUTION 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 vehi cle EAU17200 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 ona slope or on soft ground otherwise the vehicle may overturn EWA10310 5 5 EAU17231 Safety is an obligation of the owner Pe riodic inspection adjustment and lubri cation 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 EWA10320 A WARNING If you are not familiar with mainte nance work have a Yamaha
20. 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 information about motor vehicle safety from the Hotline 9 3 CONSUMER INFORMATION EAU26560 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 Exhaust system e Muffler e Exhaust pipe e Silencer Intake system e Air cleaner case e Air cleaner element e Intake duct 9 4 CONSUMER INFORMATION EAU26631 Maintenance record Copies of work orders and or receipts for parts purchased and installed on your motorcycle will b
21. dealer do it for you PERIODIC MAINTENANCE AND MINOR REPAIR AU17301 E PERIODIC MAINTENANCE PROPER PERIODIC MAINTENANCE OF YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEA SURABLE SERVICE ESPECIALLY IMPORTANT ARE THE MAINTE NANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE SERVICES REQUIRE SPECIALIZED DATA KNOWLEDGE AND EQUIP MENT YAMAHA DEALERS ARE TRAINED AND EQUIPPED TO PER FORM THESE PARTICULAR SER VICES 6 1 EAU17551 Owner s tool kit 1 Owner s tool kit 2 Rider backrest The tool kit is located inside the storage compartment behind the rider seat backrest See page 3 9 t The service information included in this manual and the tools provided in the owner s tool kit are intended to assist PERIODIC MAINTENANCE AND MINOR REPAIR 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 Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render
22. in the Owner s and Service Manual We do recommend however that items requiring special tools Will the warranty be void or cancelled if do not operate or maintain my new motor 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 against 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 lf you should move after you have purchased your new motorcycle please advise us of
23. into first gear when the motorcycle reaches 20 km h 12 5 mish If the engine is about to stall or runs very roughly pull the clutch lever in and use the brakes to stop the motorcycle OPERATION AND IMPORTANT RIDING POINTS 3 Shift the transmission into the neu tral position when the motorcycle is almost completely stopped The neutral indicator light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below Shift up points 1st 2nd 16 km h 10 mi h 2nd gt 3rd 24 km h 15 mi h 3rd 4th 32 km h 20 mi h 4th gt 5th 40 km h 25 mi h Shift down points 5th gt 4th 20 km h 12 5 mi h 4th gt 3rd 20 km h 12 5 mi h 3rd 2nd 20 km h 12 5 mi h 2nd 1st 20 km h 12 5 mi h 5 4 EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put an excessive load on it for the first 1600 km 1000 mi The various parts in the engine wear and polish themselves to the correct operating clearances During this period prolonged full throt tle operation or any condition that might result in engine overheating must be avoided EAU17121 0 1000 km 0 600 mi Avoid prolonged operation above 4500 r min 1000 1600 km
24. into the seat holder as shown 1 Opening lever 2 Remove the bolts and screws and then pull the rider seat off 1 Projection 2 Seat holder 3 9 EAU14281 Helmet holder 1 Helmet holder 2 Unlock 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 ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of con trol and possibly an accident EWA10160 INSTRUMENT AND CONTROL FUNCTIONS EAU14660 Adjusting the front fork This front fork is equipped with air valves for adjusting the spring rate EWA10180 A WARNING Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Adjust the spring rate as follows 1 Elevate the front wheel by placing the vehicle on the centerstand NOTE When checking and adjusting the air pressure there should be no weight on the front end of the vehicle 1 Front fork air valve cap 2 Front fork air valve 3 Check the air pressure in each fork leg with an air pressure gauge 2 Remove the air valve cap from each fork leg 3 10 1 Air pressure gauge NOTE An optional air pressure gauge is avail able at a Yamaha dealer INSTRUMENT AND CONTROL FUNCTIONS 4 To increase the spring rate and thereby harden the suspension
25. switch TURN 3 Horn switch HORN Right Tore 1 bec A2 P START ay 3 1 Engine stop switch ENGINE STOP 2 Fuel reserve switch FUEL 3 Start switch START EAU12410 Dimmer switch LIGHTS Set the switch to HI for the high beam and to LO for the low beam EAU12420 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 canceling system the turn signal lights will self cancel after the vehicle has traveled both about 150 m 490 ft and for approximately 15 seconds However the turn signal lights can also be canceled manually by pushing the switch in after it has returned to the cen ter position NOTE The self canceling system only oper ates when the vehicle is moving so that the turn signal lights will not self cancel while you are stopped at an intersec tion INSTRUMENT AND CONTROL FUNCTIONS EAU12510 Horn switch HORN Press this switch to sound the horn EAU12650 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 vehicle overturns or when the throttle cable is stuck EAU12690
26. the brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b 6 24 EAU22311 Checking the front and rear brake pads 1 Brake pad wear indicator 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 EAU22680 Checking the brake and clutch fluid levels Front brake 1 Minimum level mark Rear brake 1 Panel B 2 Minimum level mark PERIODIC MAINTENANCE AND MINOR REPAIR Clutch 1 Minimum level mark 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 fluid level may indicate worn brake pads and or brake system leakage If the brake le
27. up minor paint damage caused by stones etc 6 Wax all painted surfaces 7 Let the motorcycle dry completely before storing or covering it EWA11130 A WARNING Make sure that there is no oil or wax on the brakes or tires e 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 ECA10800 CAUTION _ _ __ e Apply spray oil and wax spar ingly and make sure to wipe off any excess e Never apply oil or wax to any rubber and plastic parts but treat them with a suitable care product MOTORCYCLE CARE AND STORAGE e Avoid using abrasive polishing compounds as they will wear away the paint EAU26230 Storage Short term NOTE Consult a Yamaha dealer for advice on what products to use Always store your motorcycle in a cool dry place and if necessary protect it against dust with a porous cover ECA10810 CAUTION e Storing the motorcycle in a poorly ventilated room or cover ing it with a tarp while it is still wet will allow water and humid ity to seep in and cause rust To prevent corrosion avoid damp cellars stables because of the presence of ammonia and areas where strong chemi cals are stored Long term Before storing your motorcycle for sev eral months
28. wheel brake caliper 6 Remove the brake caliper bracket bracket spacer and wheel axle and spacer 6 38 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 4 Connect the brake torque rod to the brake caliper bracket by install ing the bolt and the nut 5 Install the axle nut and then slight ly tighten it 6 Take the motorcycle off the center stand so that the rear wheel is on the ground 7 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 kgf 17 ft lbf Rear wheel axle pinch bolt 16 Nm 1 6 m kgf 11 ft lbf PERIODIC MAINTENANCE AND MINOR REPAIR 8 Install the brake torque rod cotter i EAU25870 pin i Troubleshooting ewatoszs3o Although Yamaha motorcycles receive a thorough inspection before shipment Always use a new cotter pin from the 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 mot
29. 16 m kgf 1 2 ft lbf Valve stem locknut 1 6 Nm 0 16 m kgf 1 2 ft lbf 6 22 EAU22011 Accessories and replacement parts This vehicle is not designed to pull a trailer or to be attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stability of the original design Genuine Yamaha Parts and Accessories are designed and test ed to be compatible with your vehi cle Please consider Genuine Yamaha Parts and Accessories be fore making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts man ufactured by other companies Yamaha cannot be held liable for EWA10621 any consequences caused by the use of items which have not been approved by Yamaha PERIODIC MAINTENANCE AND MINOR REPAIR EAU22071 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 level and check the hydraulic system for leakage before each ride If the clutch lever free play does become excessive and shifting becomes rough or clutch slippage occurs causing poor acceler ation there may be air in the clutch sys tem If there is air in the hyd
30. 40 CAL U49 20 10 0 10 20 30 40 50 C I I I I I I I I SAE 10W 30 SAE 10W 40 i SAE 15W 40 SAE 20W 40 SAE 20W 50 10 30 50 i 90 110 130 F tt A A 1 YAMALUBE 4 10W30 _or SAE 10W30 i i i i YAMALUBE 4 20W40 or SAE 20W40 i i Se ier eaten Bees ees i 1 1 1 1 1 1 Fe tO a Tees a 20 10 0 10 20 30 40 50 C Recommended engine oil grade API service SE SF SG type or higher Engine oil quantity Without oil filter cartridge replacement 3 50 L 3 70 US qt 3 08 Imp qt 8 1 With oil filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil or multi grade hypoid gear oil SAE80W 90 Quantity 0 20 L 0 21 US qt 0 18 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt Radiator capacity including all routes 2 75 L 2 91 US qt 2 42 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Regular unleaded gasoline only ZAF Unleaded gasoline only CAL U49 Fuel tank capacity 15 0 L 3 96 US gal 3 30 Imp gal Fuel reserve amount 3 0 L 0 79 US gal 0 66 Imp gal Carburetor Manufacturer MIKUNI Type x quantity BDS35 x 4 Spark plug s Manufacturer model NGK DPR8EA 9 Manufacturer model DENSO X24EPR U9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Clutch Clutch type Wet mul
31. Check the coolant level in the cool ant reservoir NOTE The coolant should be between the minimum and maximum level marks 1 Maximum level mark 2 Minimum level mark 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 5 Install the coolant reservoir cap and the cowling Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt ECA10470 CAUTION 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 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 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 EWA10380 Never attempt to remove the radiator cap when the engine is hot 6 15 NOTE PERIODIC MAINTENANCE AND MINOR REPAIR e The radiator fan is automatically switched on or off according to the coolant temperature in the radia tor If the engine overheats see page 6 40 for further instructions EAU20392 To change the coolant 1 2 3 4 Place th
32. EAU10270 MOTORCYCLES ARE SINGLE TRACK VEHICLES THEIR SAFE USE AND OPERATION ARE DEPEN DENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERA TOR EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE MENTS BEFORE RIDING THIS MOTORCYCLE HE OR SHE SHOULD OBTAIN THOROUGH INSTRUC TIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION e OBSERVE THE WARNINGS AND MAINTENANCE REQUIRE MENTS IN THE OWNER S MAN UAL OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES OBTAIN PROFESSIONAL TECH NICAL SERVICE AS INDICATED BY THE OWNER S MANUAL AND OR WHEN MADE NECES SARY BY MECHANICAL CONDI TIONS Safe riding Always make pre operation checks Careful checks may help prevent an accident This motorcycle is designed to carry the operator and a passen ger e The failure of motorists to detect and recognize motorcycles in traf fic 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 ap pears to be very effective in reduc ing the chance of this type of accident Therefore e Wear a brightly colored jacket e Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur e Ride where other motorists can see you Avoid ri
33. ER _ _ VMX12T C OWNER S MANUAL 2004 by Yamaha Motor Corporation U S A 1st edition April 2004 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 18 18 SAFETY INFORMATION 1 1 Location of important labels 1 5 DESCRIPTION o ae 2 1 Left view sneha eet 2 1 Right ViOW eessen 2 2 Controls and instruments 2 3 INSTRUMENT AND CONTROL FUNCTIONS 3 1 Main Switch 2eceeeceeeeeeeeeeeeeeeees 3 1 Indicator and warning lights 3 1 Speedometer unit eeceee 3 2 Tachometer eeeeesceeeseeeeeeneeeeees 3 3 Coolant temperature gauge 3 3 Handlebar switches seee 3 3 Clutch lever oo eeeeeeeeeeeseeeeeeeeerees 3 5 Shift pedal oo eee eeeeeeeeeeeeeees 3 5 Brake lever cccceecceeeeeeeeereeeeeeees 3 5 Brake pedal snac 3 6 Fuel tank Cap eccere 3 6 Buel seit ce e eea E 3 7 Starter choke lever s s s 3 8 Steering lock eeeeeeeeeeeeeeteeteees 3 8 Rider sat i i63 ccceisicapesces inate czeac edi 3 9 Helmet holder eeeeeeeeesreeeeres 3 10 Adjusting the front fork 3 10 Adjusting the shock absorber assemblies 00 ee eeeseeeeeeeeeeeeees 3 11 N BOOSlsccireiet siete oe 3 13 Sidestand ooo eeeeeeeeeeeeeeeeeaes 3 13 Ignition circuit cut off system 3 14 PRE OPERATION CHECKS
34. F with the position indicator 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 13 14 Antifreeze water mixture ratio 1 1 Recommended antifreeze High quality ethylene glycol anti freeze containing corrosion inhibitors for aluminum engines Coolant quantity Radiator capacity including all routes 2 75 L 2 91 US qt 2 42 Imp qt Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt ECA10470 CAUTION If coolant is not available use 15 Install the radiator cap start the 16 distilled water or soft tap water instead Do not use hard water or salt water since it is harmful to the engine 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 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 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 6 17 17 18 19 until it reaches the top of the radia tor and then in
35. IGATIONS 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 EAU26661 CONSUMER INFORMATION WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period PP plugs and brake shoes pe a failure No The warranty is limited to repair of the machine itself Manual instead of having the dealer do them gt Pk P or equipment be done by Yamaha Motorcycle dealer o cycle exactly as specified in the Owner s Manual A 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 Q What responsibility does my dealer have under this warranty A Each Yamaha Motorcycle dealer is e
36. ION Read owner s manual before servicing battery Electrolyte will damage metal parts or paint If electrolyte spills wash area with fresh water immediately Be sure to connect breather hose after installing battery 3JL 28177 A0 1 6 Left view Clutch fluid reservoir page 6 25 Air filter element page 6 18 Fuse box page 6 33 Main fuse box page 6 33 Owner s tool kit page 6 1 Shock absorber assembly spring preload adjusting ring page 3 11 Shock absorber assembly damping force adjusting knob page 3 11 Helmet holder page 3 10 Shift pedal page 3 5 0 Starter choke lever page 3 8 DESCRIPTION EAU10410 DESCRIPTION EAU10420 Right view Fuel tank cap page 3 6 Battery page 6 30 Coolant reservoir page 6 14 Front brake fluid reservoir page 6 25 Main switch page 3 1 Radiator cap page 6 14 Radiator page 6 14 Engine oil filter cartridge page 6 11 9 Engine oil level check window page 6 11 10 Brake pedal page 3 6 11 Rear brake fluid reservoir page 6 25 ANOaARWDND 2 2 Controls and instruments ANOaARWDND Clutch lever page 3 5 Left handlebar switches page 3 3 Speedometer unit page 3 2 Right handlebar switches page 3 3 Brake lever page 3 5 Throttle grip page 6 19 Tachometer page 3 3 Coolant temperature gauge page 3 3 2 3
37. Starter choke lever Steering lock 1 Open the San Ik cover and then insert the key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover 1 Starter choke lever 1 Steering lock Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke To lock the steering 1 Turn the handlebar all the way to the right 2 Open the steering lock cover and then insert the key 3 Turn the key 1 8 turn counterclock wise push it in while turning the handlebar slightly to the left and then turn the key 1 8 turn clock wise 4 Check that the steering is locked remove the key and then close the lock cover 3 8 INSTRUMENT AND CONTROL FUNCTIONS Ri reve 2 Place the rider seat in the original ider seat position and then tighten the bolts 2 and screws To remove the rider seat NOTE 1 Release the rider seat backrest by pushing the levers on the left and right side as shown and then slide the backrest forward Make sure that the seat is properly se cured before riding 3 Return the rider seat backrest to the original position 1 Bolt 2 Screw To install the rider seat 1 Insert the projection on the front of the rider seat
38. TENANCE AND MINOR REPAIR EAU19543 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 1 Spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit 6 9 1 Spark plug wrench To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all spark plugs installed in the engine have the same color 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 vehicle PERIODIC MAINTENANCE AND MINOR REPAIR 3 Check each spark plug for elec 2 Clean the surface of the spark plug 2 x ie trode erosion and excessive car gasket and its mating surface and Canister for California only bon or other deposits and replace then wipe off any grime from the To carburetor it if necessary spark plug threads Tex i 3 Install the spark pl
39. UMBER Oooo MODEL LABEL INFORMATION CONSUMER INFORMATION EAU26390 Key identification number OWO OVS 1 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 EAU26400 Vehicle identification number 1 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 CONSUMER INFORMATION EAU26530 Model label 1 Model label The model label is affixed under cowl ing A See page 6 8 Record the infor mation on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha dealer 9 2 CONSUMER INFORMATION EAU26550 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 immediately inform the National Highway Traffic Safety Administration 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 a group of vehicles it may order a recall and remedy campaign However
40. aired before operating the vehicle EWA11150 4 1 PRE OPERATION CHECKS Pre operation check list CHECKS EAU15602 e Check fuel level in fuel tank e Refuel if necessary e Check fuel line for leakage Engine oil e Check oil level in engine e If necessary add recommended oil to specified level e Check vehicle for oil leakage Final gear oil e Check vehicle for oil leakage Coolant e Check coolant level in reservoir e If necessary add recommended coolant to specified level e Check cooling system for leakage Front brake e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check lever free play e Adjust if necessary e Check brake pads for wear e Replace if necessary e Check fluid level in reservoir e If necessary add recommended brake fluid to specified level e Check hydraulic system for leakage 6 23 6 24 6 25 Rear brake e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check brake pads for wear e Replace if necessary e Check fluid level in reservoir e If necessary add recommended brake fluid to specified level e Check hydraulic system for leakage 4 2 PRE OPERATION CHECKS CHECKS Clutch e Check operation e If soft or spongy have Yamaha dealer bleed hydraulic system e Check fluid level in reservoir e If necessary add recommended fluid to specified le
41. arranty 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 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED 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 five 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 OBL
42. assemblies adj stiN gissen ea e aaan an Sidestand ee Spark plugs checking Specifications 0 Speedometer unit eee eee Starter choke lever ooo cece eee Starting and warming up a cold ENGNG oiv idi taa aei Start switch 7 Steering checking c cee 6 29 Steering l0CK eee eee tere eee 3 8 Storage ee ene 7 3 T TACNOMEHEl ccesccceesesrecseeeeseesseessseeees 3 3 Throttle cable free play adjusting 6 19 Throttle grip and cable checking and lubricating 0 0 6 27 INDEX Troubleshooting ee cece eeeeees 6 39 Troubleshooting charts s s s 6 40 Turn signal indicator light 3 1 Turn signal light bulb or tail brake light bulb replacing 6 35 Turn signal switch seses 3 4 V Valve clearance adjusting 0 6 19 N lt BOOSU innsatte iaia 3 13 Vehicle identification number 9 1 WwW Warranty extended 9 9 Warranty limited s 9 7 Wheel bearings checking 6 30 Wheel front Wheel rear Wheels iania a See your Authorized YAMAHA Dealer for a Genuine YAMAHA Service Manual PRINTED IN JAPAN 2004 04 0 3x1 CR E
43. ator light HIGH BEAM This indicator light comes on when the high beam of the headlight is switched on EAU32330 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 follow ing 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 INSTRUMENT AND CONTROL FUNCTIONS EAU32321 Fuel level warning light FUEL This warning light comes on when the fuel level drops below approximately 3 0 L 0 79 US gal 0 66 Imp 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 follow ing 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 3 2
44. brake Operation Right foot operation Recommended fluid DOT 4 SPECIFICATIONS Front suspension Type Telescopic fork Spring shock absorber type Coil air spring oil damper Wheel travel 140 0 mm 5 51 in Rear suspension Type Swingarm Spring shock absorber type Coil spring oil damper Wheel travel 100 0 mm 3 94 in Electrical system Ignition system Transistorized coil ignition digital Charging system A C magneto Battery Model YB16AL A2 Voltage capacity 12 V 16 0 Ah Headlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W x 1 Tail brake light 12 V 8 0 27 0 W x2 Front turn signal position light 12 V 23 W 8 0 W x 2 Rear turn signal light 12 V 21 0 Wx2 Meter lighting 14V 3 0Wx2 Neutral indicator light 14V 3 0Wx1 High beam indicator light 14V 3 0W x1 Oil level warning light 14V 3 0W x1 Turn signal indicator light 14V 3 0Wx1 Fuel level warning light 14V 3 0W x1 Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Radiator fan fuse 10 0 A 8 3 EAU26351 Identification numbers Record the key identification number vehicle identification number and mod el label information 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 KEY IDENTIFICATION NUMBER Oo i VEHICLE IDENTIFICATION N
45. can firmly place both feet on the passenger footrests e 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 Protective apparel The majority of fatalities from motor cycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the pre vention or reduction of head injuries Always wear an approved helmet e Wear a face shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations e Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or exhaust system during or after operation They become very hot and can 1 2 cause burns Always wear protec tive clothing that covers your legs ankles and feet e A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the re moval of original equipment may ren der 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 you
46. ccordance with the riding speed and with the total weight of rider passenger car go and accessories approved for this model EWA10500 Tire air pressure measured on cold tires 0 90 kg 0 198 Ib Front 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm 90 215 kg 198 474 Ib CAL ZAF 90 216 kg 198 476 Ib U49 Front 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Maximum load 215 kg 474 Ib CAL ZAF 216 kg 476 Ib U49 Total weight of rider passenger car go and accessories Proper loading of your vehicle is im portant for several characteristics of your vehicle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heavi est items close to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load EWA10510 6 20 and check the condition and pres sure of your tires NEVER OVER LOAD YOUR VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle Operation of an overloaded vehicle could cause tire damage an accident or even injury Tire inspection 3 1 Tire sidewall 2 Tire wear indicator 3 Tire tread depth Always c
47. ce e Always have a Yamaha dealer service the shock absorbers INSTRUMENT AND CONTROL FUNCTIONS EAU15270 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 ECA10170 CAUTION The V Boost was set 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 The V Boost operation can be heard when the main switch is turned on ECA10180 CAUTION If the V Boost does not operate ask a Yamaha dealer to inspect it 3 13 EAU15300 Sidestand The sidestand is located on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle 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 The vehicle must not be ridden with the sidestand down or if the side stand cannot be properly moved up or does not stay up otherwise the sidestand could contact the ground and distract the operator resulting in a possible loss of control Yamaha s_ ignition circuit cut off system has been designed to assist the operator in fulfilling the respon sibility o
48. convenient contact Yamaha with your Primary ID number your frame number We ll be YAMAHA EXTENDED SERVICE happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 9 10 A Accessories and replacement parts 6 22 Air filter element cleaning 6 18 B Battery si ceseititaeesestsvaserertiseds Gutasttroarates 6 30 Brake and clutch fluid levels CHECKING witiviciecastiedciseiasievetidstietees 6 25 Brake and clutch fluids changing 6 26 Brake and clutch levers checking and lubricating 6 28 Brake and shift pedals checking and lubricating 6 27 Brake lever cc seceeesceesesseeeeees we 3 5 Brake lever free play adjusting 6 23 Brake pedal eee cece eee eeeeeeee 3 6 Cc Cables checking and lubricating 6 26 Canister for California only 6 10 Carburetors adjustment Centerstand and sidestand checking and lubricating 00 6 28 Clutch lever Clutch lever free play S Coolant sasinan aeti Coolant temperature gauge 0 3 3 Cowling and panels removing and installing 6 8 D Dimmer SWitCH ooo eee eee reece 3 4 E Engine break in 0 0 eee eee eeee eee 5 4 Engine oil and oil filter cartridge 6 11 Engine starting a Warm 5 3 Engine stop switch eee 3 4 F Final gear Oil eee eee eeee
49. ding in another motorist s blind spot Many accidents involve inexperi enced operators In fact many op erators who have been involved in accidents do not even have a cur rent motorcycle license Make sure that you are qualified and that you only lend your motorcycle to other qualified op erators Know your skills and limits Staying within your limits may help you to avoid an accident We recommend that you prac tice riding your motorcycle where there is no traffic until you have become thoroughly famil iar 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 A SAFETY INFORMATION turn due to EXCESSIVE SPEED or undercornering insufficient lean angle for the speed e Always obey the speed limit and never travel faster than warrant ed by road and traffic conditions e 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 The operator should keep both hands on the handlebar and both feet on the operator foot rests during operation to main tain control of the motorcycle 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 Never carry a passenger unless he or she
50. dlight 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 po sition and then secure it with the bulb holder ECA10660 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 al cohol 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 EAU24281 Replacing a turn signal light bulb or the tail brake light bulb 1 Remove the lens by removing the screws 1 Turn signal light bulb 2 Remove the defective bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the Screws ECA10680 CAUTION Do not overtighten the screws oth erwise the lens may break 1 Tail brake light bulb 6 35 PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel OQ eee K To remove the front wheel oe LSS OES It
51. e 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 Mileage Servicing dealer Remarks interval service name and address 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 km or 42 months 32000 mi 49000 km or 48 months CONSUMER INFORMATION Maintenance interval Mileage Servicing dealer name and address Remarks 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months 9 6 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 herein 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 a
52. e vehicle on the center stand and let the engine cool if necessary Remove cowling A and panel A See page 6 8 Place a container under the engine to collect the used coolant Remove the radiator cap EWA10380 Never attempt to remove the radiator cap when the engine is hot PERIODIC MAINTENANCE AND MINOR REPAIR 1 Radiator cap 1 Water pump drain bolt 1 Rubber coolant drain plug 5 Turn the coolant drain cock mak 7 Remove the cylinder drain plug 9 After the coolant is completely ing sure to align the ON with the covers on the outside of the cylin drained thoroughly flush the cool position indicator der blocks by removing the ing system with clean tap water screws 10 Install the water pump drain bolt and then tighten it to the specified torque NOTE Check the washer for damage and re place it if necessary Tightening torque Water pump drain bolt 43 Nm 4 3 m kgf 31 ft lbf 1 Coolant drain cock 2 Position indicator 1 Screw 11 Install the rubber coolant drain plugs and then install the cylinder drain plug covers 6 Remove the water pump drain bolt 8 Remove the rubber coolant drain to drain the water pump housing plugs to drain the coolant from the engine 6 16 PERIODIC MAINTENANCE AND MINOR REPAIR NOTE Check the rubber plugs for damage and replace them if necessary 12 Turn the coolant drain cock mak ing sure to align the OF
53. eck the cause EAU22750 Changing the brake and clutch fluids Have a Yamaha dealer change the brake 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 Oil seals years e Brake and clutch hoses Replace every four years Replace every two 6 26 EAU23090 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 EWA10710 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 EAU23110 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 PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 Checking and lubricat
54. ectric starter The engine turns over The engine turns over F quickly The battery is good Check the electrolyte and battery tj lead connections and charge the slowly i wy battery if necessary 6 40 The engine does not start Have a Yamaha dealer check the vehicle PERIODIC MAINTENANCE AND MINOR RERAIR Sn EAU25941 EWA10840 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 hissing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap a There is Have a Yamaha dealer check The coolant level is low leakage and repair the cooling system m Check the cooling system for leakage There is Wait until the Check the coolant level in the gt no leakage Add coolant Sge NOTE engine has cooled reservoir and radiator f EWA10400 The coolant level Start the engine If the engine overheats again have a is OK Yama
55. eeeee 6 13 Front and rear brake pads checking 6 24 Front fork adjusting eee eee Front fork checking Fuel aaa namai Fuel level warning light Fuel reserve switch x Fuel tank Cap eeseeeereserrrerrernreerrnre Fuses replacing eee eee cence eee H Handlebar switches Headlight bulb replacing ee Helmet holder High beam indicator light 3 2 Horn SWItCH eeeeeeee cece ee eeteeeeeeeeeeeeneeees 3 4 l Identification NUM ETrS eeeeeeees 9 1 Ignition circuit cut off system 3 14 Indicator and warning lights 0 0 3 1 K Key identification number 9 1 L Labels location Of ccccceessseeeeeeees 1 5 M Main SWItCH aesir 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance periodic 00 cceeeee 6 1 Maintenance record 9 5 Model label 9 2 N Neutral indicator light ee 3 1 Noise regulation eee eee eens 9 4 0 Oil level warning light ee 3 2 P ellae PAE AAE E E EEE 5 5 Part locations sisiiveniisi siiin 2 1 Pre operation check list ee 4 2 R Rear brake light switch adjusting 6 24 Rear suspension lubricating Rider Seat wesc wecicessevinscisccnteenversecctersects S Safety defects reporting 9 3 Safety information 1 1 Shifting Shift pedale areara 3 5 Shock absorber
56. er than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray 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 7 1 thinner fuel gasoline rust re movers or inhibitors brake flu id antifreeze or electrolyte 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 switches and lights breather hoses and vents For motorcycles equipped with a windshield Do not use strong cleaners or hard sponges as they will cause dulling or scratching Some cleaning com pounds for plastic may leave scratches on the windshield Test the product on a small hid den part of the windshield to make sure that it does not leave any marks If the windshield is scratched use a quality 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 toothb
57. er to see how comforting uninterrupted factory backed protection can be 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 9 150 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 CONSUMER INFORMATION We urge you 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 A special note If visiting your dealer isn t
58. estand down Does the engine stall INSTRUMENT AND CONTROL FUNCTIONS NOTE This check is most reliable if performed with a warmed up engine 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 15 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 CHECKS EAU15591 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 NOTE Pre operation checks should be made each time the vehicle 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 rep
59. f raising the sidestand be fore starting off Therefore check this system regularly as described EWA10240 INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer re laniti j it cut off iem pair it if it does not function proper gni ion circul CUL OTT syste ly The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in gear and the side stand is up but the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down Itcuts the running engine when the transmission is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure 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 EWA10260 3 14 With the engine turned off 1 Move the sidestand down 2 Make sure that the engine stop switch is turned on 3 Turn the key 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 sid
60. ha 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 41 MOTORCYCLE CARE AND STORAGE EAU26060 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 motor cycle 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 2 Make sure that all caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 3 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 Always rinse the dirt and de greaser off with water Cleaning ECA10770 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 long
61. hat it is kept upright If the motorcycle should lean over gasoline may leak out of the carburetor or fuel tank If you should swallow any gaso line 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 4 A SAFETY INFORMATION AU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 12 3 4 5 A SAFETY INFORMATION AWARNING BEFORE YOU OPERATE THIS VEHICLE READ TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing FRONT 225 kPa 2 25 kgf cm 33 psi REAR 225 kPa 2 25 kgf cm 33 psi 90 kg 198 Ibs maximum load 2 CALIFORNIA ON LY FRONT 225 kPa 2 25 kgf cm 33 psi REAR 250 kPa 2 50 kgf cm 36 psi EMISSION HOSE ROUTING 5BN 21668 00 SGK 2118K 00 FROM FUEL TANK AWARNING PASS LEAD WIRES THROUGH HOLE CANISTER as shown A short circuit could result TO ATMOSPHERE from improper routing This could cause the engine to stop running and lights to fail which could result in an accident 4YN 21686 00 3JP 2415H A0 CAUT
62. heck 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 sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced Minimum tire tread depth front and rear 1 0 mm 0 04 in EWA10580 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately e The replacement of all wheel and brake related parts includ ing the tires should be left to a Yamaha dealer who has the necessary professional knowl edge and experience Tire information This motorcycle is equipped with tube less tires and cast wheels PERIODIC MAINTENANCE AND MINOR REPAIR EWA10460 e The front and rear tires should be of the same make and de sign otherwise the handling characteristics of the vehicle cannot be guaranteed e After extensive tests only the tires listed below have been ap proved for this model by Yamaha Motor Co Lid Front tire Size 110 90 18M C 61V Manufacturer model BRIDGESTONE G525 DUNLOP F20 Rear tire Size 150 90 15M C 74V Manufacturer model BRIDGESTONE G526 DUNLOP K525 6 21 EWA10600 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
63. hown 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 6 32 1 Positive battery lead red 2 Starter motor lead black 14 Connect and tighten the negative battery lead to the battery 15 Install the rider seat To store the battery 1 If the vehicle will not be used for more than one month remove the battery fully charge it and then place it in a cool dry place 2 Ifthe battery will be stored for more than two months check the specif ic gravity of the electrolyte at least once a month and fully charge the battery whenever necessary 3 Fully charge the battery before in stallation 4 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 ECA10600 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 Replacing the fuses EAU23570 The main fuse box is located under the rider seat See page 3 9 t nepen 1 Main fuse 2 Spare main fuse o OO The fuse box which contains the fuses for the indi
64. ing the Recommended lubricant Lithium soap based grease all pur brake and shift pedals pose grease INY The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary 6 27 PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23210 Checking and lubricating the centerstand and sidestand 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 pur pose grease 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 EWA10740 Recommended lubricant Lithium soap based grease all pur pose grease 6 28 EAU23250 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 EAU23271 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 te
65. is advisable to have a Yamaha dealer service the wheel e Securely support the motor cycle so that there is no danger 1 speedometer cable 2 Lift the wheel up between the fork of it falling over 2 Bolt TDi the tI nn ab 3 Front wheel axle pinch bolt egs 1 Place the motorcycle on the cen A eels NOTE terstand f 2 Disconnect the speedometer ca 5 Pull the wheel axle out and then Make sure that the slot in the speedom 6 ble from the front wheel remove the wheel eter gear unit fits over the retainer on 3 Remove the brake calipers by re the fork leg moving the bolts PORE ccattoeo TO install the front wheel l CAUTION 1 sia eer ardent ra unit a ee ee ee into the wheel hub so that the pro Do not pull the brake lever after the jections mesh with the slots P 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 1 Retainer 3 Insert the wheel axle 6 36 PERIODIC MAINTENANCE AND MINOR REPAIR 4 Install the brake calipers by install R agi EAU25080 ing the bolts ear wnee NOTE EAU25100 Make sure that there is enough space TO remove the rear wheel between the brake pads before install A WARNING ing the brake calipers onto the brake EWA10820 discs Itis advisable to have a Yamaha dealer service the wheel 5 Take the motorcycle off the center e Securely support the motor stand so that
66. l other accessories that may be available you must personally be re sponsible for the proper selection in stallation and use of non Yamaha accessories Use extreme caution when selecting and installing any ac cessories Keep the following guidelines in mind as well as those provided under Load ing when mounting accessories e Never install accessories or carry cargo that would impair the perfor mance 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 e Accessories fitted to the handle bar or the front fork area can create instability due to improper weight distribution or aerody namic changes If accessories 1 3 are added to the handlebar or front fork area they must be as lightweight as possible and should be kept to a minimum Bulky or large accessories may seriously affect the stability of the motorcycle due to aerody namic effects Wind may at tempt to lift the motorcycle or the motorcycle may become un stable in cross winds These ac cessories may also cause instability when passing or being passed by large vehicles e Certain accessories can dis place the operator from his or her normal riding position This improper position limits the free dom of movement of the opera tor and may limit co
67. nance and lubrication chart To check the condition Securely support the vehicle so that there is no danger of it falling over EWA10750 Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds smoothly PERIODIC MAINTENANCE AND MINOR REPAIR ECA10590 CAUTION If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it 6 29 EAU23280 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 vehicle so that there is no danger of it falling over EWA10750 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 steering PERIODIC MAINTENANCE AND MINOR REPAIR Q EAU23290 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 the
68. nction 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 e Before starting out make sure that the sidestand is up If the sidestand is not raised com pletely it could contact the ground and distract the opera tor resulting in a possible loss of control EAU32300 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 The transmission is in gear with the clutch lever pulled and the sid estand up 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 14 e Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to RUN EWA10290 ECA10220 CAUTION If the fuel level warning light comes on check the fuel level and if nec essary refuel as soon as possible 5 1 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
69. nt ECA10400 CAUTION If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha dealer check the vehicle 10 Turn the engine off and then check the oil level and correct it if necessary 6 13 PERIODIC MAINTENANCE AND MINOR REPAIR EAU20000 Final gear 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 vehicle In addi tion the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrica tion chart Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel EWA10370 To check the final gear oil level 1 Place the vehicle on the center stand NOTE The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading PERIODIC MAINTENANCE AND MINOR REPAIR 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 1 Final gear oil filler bolt 2 Correct oil level 3 Final gear oil drain bolt 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 cor
70. ntrol ability therefore such accessories are not recommended Use caution when adding electri cal accessories If electrical acces sories 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 A SAFETY INFORMATION Gasoline and exhaust gas e GASOLINE IS HIGHLY FLAMMA Do not park the motorcycle on a slope or soft ground otherwise it BLE may fall over 1 e Always turn the engine off when Do not park the motorcycle near refueling a flammable source e g a ker Take care not to spill any gaso line on the engine or exhaust system when refueling 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 ad equate ventilation Always turn the engine off before leaving the motorcycle unattended and remove the key from the main switch When parking the motor cycle note the following e The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas osene heater or near an open flame otherwise it could catch fire When transporting the motorcycle in another vehicle make sure t
71. of the ad justing ring with the appropriate setting on the shock absorber e Use the special wrench included in the owner s tool kit to make this ad justment Spring preload Minimum soft 1 Standard 1 Maximum hard 5 Damping force 1 Damping force adjusting knob 2 Position indicator INSTRUMENT AND CONTROL FUNCTIONS To increase the damping force and thereby harden the damping turn the adjusting knob on each shock absorber assembly in direction a To decrease the damping force and thereby soften the damping turn the adjusting knob on each shock absorber assembly in di rection b NOTE Align the appropriate setting on the ad justing knob with the position indicator on the shock absorber Damping force Minimum soft 1 Standard 1 Maximum hard 4 EWA10230 These shock absorbers contain highly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorbers The manufacturer cannot be held re 3 12 sponsible for property damage or personal injury that may result from improper handling e Do not tamper with or attempt to open the gas cylinders e Do not subject the shock ab sorbers to an open flame or oth er high heat sources otherwise they may explode due to exces sive gas pressure e Do not deform or damage the gas cylinders in any way as this will result in poor damping per forman
72. 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 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase PERIODIC MAINTENANCE AND MINOR REPAIR NOTE The engine oil should be between the minimum and maximum level marks te YC R 1 2 C3 1 Engine oil level check window 2 Maximum level mark 3 Minimum level mark 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 To change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for several minutes and then turn it off 6 11 2 Place an oil pan under the engine to collect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase 1 Engine oil drain bolt PERIODIC MAINTENANCE AND MINOR REPAIR NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench 1 Oil filter cartridge 2 Oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge
73. orcycle 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 inferi or have a shorter service life and can lead to expensive repair bills 6 39 Troubleshooting charts Starting problems or poor engine performance Keep away open flames and do not smoke while checking or working on the fuel system 1 Fuel Check the fuel level in the fuel tank There is enough fuel Check the compression 2 Compression There is no fuel Supply fuel gt The engine does not start Check the compressoin m Operate the electric starter There is compression Check the ignition 3 Ignition e Have a Yamaha dealer There is no compression gt R check the vehicle Remove the spark plugs and check the electrodes Ww Wipe off with a dry cloth and correct the et m spark plug gaps or replace the spark plugs Open the throttle halfway and operate the electric starter t 4 Battery Dry Have a Yamaha dealer check the vehicle The engine does not start Check the battery Operate the el
74. pedal down repeatedly until it reaches the end of its travel and then slightly raise it 5 3 ECA10260 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 e Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which are not designed to withstand the shock of forced shifting EAU16680 To start out and accelerate 1 Pull the clutch lever to disengage the clutch 2 Shift the transmission into first gear The neutral indicator light should go out 3 Open the throttle gradually and at the same time release the clutch lever slowly 4 At the recommended shift points shown in the following table close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear NOTE Always shift gears at the recommended shift points EAU16700 To decelerate 1 Apply both the front and the rear brakes to slow the motorcycle 2 Shift the transmission
75. r motorcycle can adversely affect stabili ty and handling if the weight distribution of the motorcycle is changed To avoid the possibility of an accident use ex treme 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 acces sories to your motorcycle Loading The total weight of the operator pas senger accessories and cargo must not exceed the maximum load limit of 215 kg 474 Ib CAL ZAF 216 kg 476 lb U49 When loading within this weight limit keep the following in mind Cargo and accessory weight should be kept as low and close to the motorcycle as possible Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal ance or instability Shifting weights can create a sud den imbalance Make sure that ac cessories and cargo are securely attached to the motorcycle before riding Check accessory mounts and cargo restraints frequently e 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 A SAFETY INFORMATION Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test al
76. raulic system have a Yamaha dealer bleed the system before operating the motor cycle 6 23 EAU22092 Adjusting the brake lever free play 1 Locknut 2 Brake lever free play adjusting screw 3 Brake lever free play The brake lever free play should mea sure 2 0 5 0 mm 0 08 0 20 in as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting screw in di rection a To decrease the brake lever free play turn the adjusting screw in direction b 3 Tighten the locknut PERIODIC MAINTENANCE AND MINOR REPAIR EWA10630 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 presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU22270 Adjusting the rear brake light switch 1 Rear brake light switch 2 Rear brake light switch adjusting nut 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
77. re is play in the wheel hub or if the wheel does not turn smoothly have a Yamaha dealer check the wheel bearings 6 30 EAU23351 Battery 1 Battery 2 Battery breather hose 3 Pass through the cable guide A poorly maintained battery will corrode and discharge quickly The electrolyte 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 To check the electrolyte level 1 Place the vehicle on the center stand PERIODIC MAINTENANCE AND MINOR REPAIR NOTE Make sure that the vehicle is positioned straight up when checking the electro lyte level 2 Check the electrolyte level in the battery NOTE The electrolyte should be between the minimum and maximum level marks Maximum level mark Minimum level mark N 3 If the electrolyte is at or below the minimum level mark continue with the following steps 4 Remove the rider seat See page 3 9 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 1 Starter motor lead black 2 Positive battery lead red 3 Negative battery lead 7 Disconnect the couplers shown 8 Remove the ignition coil assem blies by removing the bolts 6 31 1 Ignition coil assembly 2 Bolt 3 Coupler
78. rect level To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 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 Nm 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 20 L 0 21 US qt 0 18 Imp qt NOTE GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used EAU20070 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 EAU20241 To check the coolant level 1 Place the vehicle on the center stand and hold it in an upright po sition 2 Remove cowling A See page 6 8 NOTE e The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 5 Install and tighten the filler bolt 6 Check the final gear case for oil leakage If oil is leaking check for the cause 6 14 3
79. rs caliper cylinders and clutch release cylinder every two years e Replace the brake and clutch hoses every four years or if cracked or damaged 6 7 PERIODIC MAINTENANCE AND MINOR REPAIR EAU18721 Removing and installing the cowling and panels The cowling and panels 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 re moved and installed 1 Cowling A 2 Panel A 3 Panel B EAU19120 Cowling A To remove the cowling 1 Insert the key into the lock and then turn it clockwise 2 Push down on the rear of the cowl ing until it locks in place 3 Remove the key from the lock EAU19180 Panel A To remove the panel 1 Remove cowling A See page 6 8 2 Remove the screws and then take the panel off 1 Unlock 2 Pull the cowling off as shown To install the cowling 1 Align the holders under the cowl ing with the projections on the frame oy 1 Screw To install the panel _ Q O 1 Place the panel in the original posi O 0 tion and then install the screws 4 Holder 2 Install the cowling 2 Projection 6 8 EAU19210 Panel B To remove the panel Remove the screws and then take the panel off 1 Screw To install the panel Place the panel in the original position and then install the screws PERIODIC MAIN
80. rush 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 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 wa ter and a mild detergent after the engine has cooled down MOTORCYCLE CARE AND STORAGE ECA10790 CAUTION Do not use warm water 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 After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome and nickel plat ed surfaces 4 Use spray oil as a universal clean er to remove any remaining dirt 7 2 5 Touch
81. stall 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 dealer check the cooling system Install the cowling and the panel PERIODIC MAINTENANCE AND MINOR REPAIR EAU20510 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart Clean the air filter element more fre quently if you are riding in unusually wet or dusty areas 1 Remove cowling A See page 6 8 2 Remove the air filter case cover by removing the screws 1 Screw 3 Pull the air filter element out 1 Air filter element 4 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 5 Insert the air filter element into the air filter case ECA10480 CAUTION Make sure that the air filter ele ment is properly seated in the air filter case 6 18 The engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 6 Install the air filter case cover by in stalling the screws 7 Ins
82. t brake pull the lever toward the handle bar grip EAU12941 Brake pedal lips O O 5 o 1 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal INSTRUMENT AND CONTROL FUNCTIONS EAU13060 Fuel tank cap To remove the fuel tank cap 1 Opening lever 1 Push the levers on the left and right side of the rider seat backrest as shown and slide the rider seat backrest forward 1 Unlock 3 6 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 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 EWA10130 INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel 1 Fuel tank filler tube 2 Fuel level Make sure that there is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown
83. tall the cowling PERIODIC MAINTENANCE AND MINOR REPAIR EAU21270 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 Yamaha dealer who has the necessary profes sional knowledge and experience EAU21380 Adjusting the throttle cable free play 1 Throttle cable free play The throttle cable free play should mea sure 3 0 5 0 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 19 EAU21400 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 EAU32380 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 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 ad justed in a
84. the front wheel is on cycle so that there is no danger 4 Rear wheel axle pinch bolt the ground of it falling over 6 Tighten the wheel axle then the ee Gc aRIGT ARI Gen 2 Place the motorcycle on the cen front wheel axle pinch bolt and the E ae ne net ah i terstand l brake caliper bolts to the specified COSE ME TEAT ORS AXE PING 3 Remove the brake caliper by re torques bolt moving the bolts 4 Disconnect the brake torque rod GG from the brake caliper bracket by removing the cotter pin the nut and the bolt Tightening torques Wheel axle 58 Nm 5 8 m kgf 42 ft lbf Front wheel axle pinch bolt 20 Nm 2 0 m kgf 14 ft Ibf Brake caliper bolt 40 Nm 4 0 m kgf 29 ft Ibf 7 Connect the speedometer cable 8 Push down hard on the handlebar several times to check for proper fork operation 1 Axle nut 6 37 PERIODIC MAINTENANCE AND MINOR REPAIR 7 Pull the wheel to the right to sepa rate it from the final gear case and then remove it ECA11180 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 1 Nut 2 Cotter pin EAU25500 3 Brake torque rod To install the rear wheel 4 Bolt 1 Apply a light coating of lithium 5 Spacer soap based grease to the splines 6 Brake caliper bracket of the final gear case and wheel 5 While supporting the rear wheel pull the wheel axle out 2 Install the
85. the vehicle unsafe for use Consult a Yamaha dealer before at tempting any changes EWA10340 6 2 PERIODIC MAINTENANCE AND MINOR REPAIR ROUTINE INITIAL Periodic maintenance chart for the emission control system ODOMETER READINGS EAU17600 600 mi 1 month 4000 mi 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months Fuel line e Check fuel hoses for cracks or damage e Replace if necessary Fuel filter e Replace Replace Spark plugs e Check condition e Adjust gap and clean e Replace every 8000 mi 13000 km or 12 months Replace Replace Valve clearance e Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km Crankcase breather system e Check breather hose for cracks or damage e Replace if necessary Carburetor synchro nization e Adjust synchronization of carbu retors Idle speed e Check and adjust engine idle speed Exhaust system e Check for leakage e Tighten if necessary e Replace gasket s if necessary Evaporative emis sion control system For California only e Check control system for dam age e Replace if necessary 6 3 Since these items require special tools data and technical skills have a Yamaha dealer perform the service
86. tiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 87 49 1 776 Secondary reduction system Shaft drive Secondary reduction ratio 21 27 x 33 09 2 852 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio tst 43 17 2 529 2nd 39 22 1 773 3rd 31 23 1 348 4th 28 26 1 077 5th 26 28 0 928 Chassis Frame type Double cradle Caster angle 29 00 Trail 119 0 mm 4 69 in Front tire Type Tubeless Size 110 90 18M C 61V Manufacturer model BRIDGESTONE G525 Manufacturer model DUNLOP F20 Rear tire Type Tubeless Size 150 90 15M C 74V Manufacturer model BRIDGESTONE G526 Manufacturer model DUNLOP K525 Loading Maximum load 215 kg 474 Ib CAL ZAF 216 kg 476 Ib U49 Total weight of rider passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 Ib Front 225 kPa 33 psi 2 25 kgf cm 8 2 SPECIFICATIONS Rear 225 kPa 33 psi 2 25 kgf cm Loading condition 90 215 kg 198 474 Ib CAL ZAF 90 216 kg 198 476 Ib U49 Front 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 18M C x MT2 15 Rear wheel Wheel type Cast wheel Rim size 15M C x MT3 50 Front brake Type Dual disc brake Operation Right hand operation Recommended fluid DOT 4 Rear brake Type Single disc
87. ug with the Specified spark plug spark plug wrench and then tight gt tank NGK DPR8EA 9 en it to the specified torque FU DENSO X24EPR U9 Tightening torque To install a spark plug Spark plug 1 Measure the spark plug gap with a 18 Nm 1 8 m kgf 13 ft Ibf wire thickness gauge and if nec essary adjust the gap to specifica NOTE tion If a torque wrench is not available when yo wey installing a spark plug a good estimate caf OF 6 of the correct torque is 1 4 1 2 turn To atmosphere O Vent hose past finger tight However the spark plug should be tightened to the speci fied torque as soon as possible This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere 1 4 Install the spark plug cap Check each hose connection Check each hose and canister for cracks or damage Replace if dam aged 1 Spark plug gap Make sure the vent hose is not blocked Clean it if necessary Spark plug gap 0 8 0 9 mm 0 031 0 035 in 6 10 EAU19871 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 vehicle on the center stand NOTE Make sure that the vehicle is positioned straight up when checking the
88. uthorized 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 oap SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance CONSUMER INFORMATION 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 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 w
89. vel e Check hydraulic system for leakage 6 23 6 25 Throttle grip e Make sure that operation is smooth e Check cable free play e If necessary have Yamaha dealer adjust cable free play and lubricate cable and grip housing Control cables e Make sure that operation is smooth e Lubricate if necessary Wheels and tires e Check for damage e Check tire condition and tread depth e Check air pressure e Correct if necessary 6 20 6 22 Brake and shift pedals e Make sure that operation is smooth e Lubricate pedal pivoting points if necessary Brake and clutch levers e Make sure that operation is smooth e Lubricate lever pivoting points if necessary Centerstand sidestand e Make sure that operation is smooth e Lubricate pivots if necessary Chassis fasteners e Make sure that all nuts bolts and screws are properly tightened e Tighten if necessary Instruments lights signals and switches e Check operation e Correct if necessary Sidestand switch e Check operation of ignition circuit cut off system e If system is defective have Yamaha dealer check vehicle Battery e Check fluid level e Fill with distilled water if necessary 4 3 OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 e Become thoroughly familiar with all operating controls and their functions before riding Consult a Yamaha dealer re garding any control or fu
90. vel is low be sure to check the brake pads for wear and the brake sys tem for leakage NOTE The rear brake fluid reservoir is located behind panel B See page 6 8 Observe these precautions 6 25 When checking the fluid level make sure that the top of the brake or clutch fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Recommended brake and clutch flu id DOT 4 brake fluid 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 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 en ter the brake or clutch fluid reser voir when refilling Water will PERIODIC MAINTENANCE AND MINOR REPAIR 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 e As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer ch
91. vidual circuits is located un der cowling A See page 6 8 6 33 NOs cS 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Radiator fan fuse 5 Spare fuse If a fuse is blown replace it as follows Go 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 PERIODIC MAINTENANCE AND MINOR REPAIR EAU23780 Specified fuses Replacing the headlight bulb Wan ae This model is equipped with a quartz Headlight fuse bulb headlight If the headlight bulb 15 0A burns out replace it as follows Signaling system fuse 1 Remove the headlight unit by re 10 0A moving the screws Radiator fan fuse 10 0A Ignition fuse 10 0A 1 Headlight bulb holder 3 Remove the headlight bulb holder by turning it counterclockwise and then remove the defective bulb ECA10640 CAUTION Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 2 Disconnect the headlight coupler and then remove the bulb cover 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 lf the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Do not touch the glass part of the bulb 6 34 EWA10790 Hea
92. w WARNING instructions could result in severe injury or death to the A WARNING motorcycle operator a bystander or a person inspecting or repairing the motor cycle 7 A CAUTION indicates special precautions that must be taken to avoid damage to CAUTION 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 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES EWA10010 IMPORTANT MANUAL INFORMATION 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 RELIABILITY OF THIS MOTORCYCLE IMPORTANT MANUAL INFORMATION EAU10192 LABEL HERE B AFFIX DEAL
93. xpected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty 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 Q Is the warranty transferable to second owners A 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 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 What are some examples of abnormal strain neglect or abuse These terms are general and overlap 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 May perform any or all of the recommended maintenance shown in the Owner s Yes if you are a qualified mechanic and follow the procedures specified
94. 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 EAU26750 YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty e In addition Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to 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 36 months or on certain models even 48 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 or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha deal

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