Yamaha 2003 VMAX Owner's Manual

OWNER’S MANUAL
VMX12R
VMX12RC
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2002.05-0.9×1 CR
(E)
LIT-11626-16-20
5GK-28199-13
EAU03438
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EAU00002
INTRODUCTION
Congratulations on your purchase of the Yamaha VMX12/VMX12C. This model is
the result of Yamaha’s vast experience in the production of fine sporting, touring, and
pacesetting racing machines. It represents the high degree of craftsmanship and
reliability that have made Yamaha a leader in these fields.
This manual will give you an understanding of the operation, inspection, and basic
maintenance of this motorcycle. If you have any questions concerning the operation
or maintenance of your motorcycle, please consult a Yamaha dealer.
The design and manufacture of this Yamaha motorcycle fully comply with the 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.
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IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death to the
motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.
WARNING
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the
motorcycle.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
NOTE:
● This manual should be considered a permanent part of this motorcycle and should remain
with it even if the motorcycle is subsequently sold.
● 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.
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IMPORTANT MANUAL INFORMATION
EW000000
WARNING
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 MOTORCYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING
SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE.
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IMPORTANT MANUAL INFORMATION
AFFIX DEALER
LABEL HERE
EAU04247
VMX12R/VMX12RC
OWNER’S MANUAL
©2002 by Yamaha Motor Corporation, U.S.A.
1st edition, April 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in Japan.
P/N LIT-11626-16-20
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TABLE OF CONTENTS
EAU00009
1 SAFETY INFORMATION
1
2 DESCRIPTION
2
3 INSTRUMENT AND CONTROL FUNCTIONS
3
4 PRE-OPERATION CHECKS
4
5 OPERATION AND IMPORTANT RIDING POINTS
5
6 PERIODIC MAINTENANCE AND MINOR REPAIR
6
7 MOTORCYCLE CARE AND STORAGE
7
8 SPECIFICATIONS
8
9 CONSUMER INFORMATION
9
INDEX
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SAFETY INFORMATION
Safe riding .......................................................................................... 1-1
Protective apparel .............................................................................. 1-3
Modifications ...................................................................................... 1-3
Loading and accessories ................................................................... 1-3
Gasoline and exhaust gas.................................................................. 1-5
Location of important labels ............................................................... 1-7
1
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SAFETY INFORMATION
EAU00014*
1-
1
MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF
THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE.
HE OR SHE SHOULD:
1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF
MOTORCYCLE OPERATION.
2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.
4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL
AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.
Safe riding
1. Always make pre-operation checks. Careful checks may help prevent an accident.
2. This motorcycle is designed to carry the operator and a passenger.
3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of
automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who
did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the
chance of this type of accident.
Therefore:
a. Wear a brightly colored jacket.
b. Use extra caution when you are approaching and passing through intersections, since intersections are the most likely places for motorcycle accidents to occur.
c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.
1-1
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SAFETY INFORMATION
4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in
accidents do not even have a current motorcycle license.
a. Make sure that you are qualified and that you only lend your motorcycle to other qualified operators.
b. Know your skills and limits. Staying within your limits may help you to avoid an accident.
c. We recommend that you practice riding your motorcycle where there is no traffic until you have
become thoroughly familiar with the motorcycle and all of its controls.
5. Many accidents have been caused by error of the motorcycle operator. A typical error made by the
operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean
angle for the speed).
a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions.
b. Always signal before turning or changing lanes. Make sure that other motorists can see you.
6. The posture of the operator and passenger is important for proper control.
a. The operator should keep both hands on the handlebar and both feet on the operator footrests
during operation to maintain control of the motorcycle.
b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with
both hands and keep both feet on the passenger footrests.
c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.
7. Never ride under the influence of alcohol or other drugs.
8. This motorcycle is designed for on-road use only. It is not suitable for off-road use.
1-2
1
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SAFETY INFORMATION
Protective apparel
1
The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety
helmet is the single most critical factor in the prevention or reduction of head injuries.
1. Always wear an approved helmet.
2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard.
3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abrasions or lacerations.
4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels
and cause injury or an accident.
5. Never touch the engine or exhaust system during or after operation. They become very hot and can
cause burns. Always wear protective clothing that covers your legs, ankles, and feet.
6. A passenger should also observe the above precautions.
Modifications
Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,
may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also
make your motorcycle illegal to use.
Loading and accessories
Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight
distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution
when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has
added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding accessories to your motorcycle:
1-3
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SAFETY INFORMATION
Loading
The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load
limit of VMX12: 476 lb (216 kg) / VMX12C: 474 lb (215 kg). When loading within this weight limit, keep
the following in mind:
1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make
sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely
attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.
3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, including such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow
steering response.
Accessories
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since
Yamaha cannot test all other accessories that may be available, you must personally be responsible for
the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.
Keep the following guidelines in mind, as well as those provided under “Loading” when mounting accessories.
1. Never install accessories or carry cargo that would impair the performance of your motorcycle. Carefully 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 obscure lights or reflectors.
1-4
1
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SAFETY INFORMATION
1
a. Accessories fitted to the handlebar or the front fork area can create instability due to improper
weight distribution or aerodynamic changes. If accessories are added to the handlebar or front
fork area, they must be as lightweight as possible and should be kept to a minimum.
b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic
effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross
winds. These accessories may also cause instability when passing or being passed by large vehicles.
c. Certain accessories can displace the operator from his or her normal riding position. This improper position limits the freedom of movement of the operator and may limit control ability, therefore,
such accessories are not recommended.
2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the
motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of
lights or engine power.
Gasoline and exhaust gas
1. GASOLINE IS HIGHLY FLAMMABLE:
a. Always turn the engine off when refueling.
b. Take care not to spill any gasoline on the engine or exhaust system when refueling.
c. Never refuel while smoking or in the vicinity of an open flame.
2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your
motorcycle in an area that has adequate ventilation.
3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the
main switch. When parking the motorcycle, note the following:
1-5
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SAFETY INFORMATION
a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pedestrians or children are not likely to touch these hot areas.
b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.
c. Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open
flame), otherwise it could catch fire.
4. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motorcycle should lean over, gasoline may leak out of the carburetor or fuel tank.
5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your
eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash
the affected area with soap and water and change your clothes.
1-6
1
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SAFETY INFORMATION
EAU02977
Location of important labels
1
Please read the following important labels carefully before operating this motorcycle.
1-7
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SAFETY INFORMATION
4
1
California only
1
2
CAUTION
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.
5
3JL-28177-A0
WARNING
PASS LEAD WIRES THROUGH HOLE,
3
TIRE INFORMATION
HOLE
Cold tire normal pressure should be set as
follows.
Up to 90 kg (198 lbs) load
FRONT
REAR
3JP-2415H-A0
kgf/cm2},
33 psi
: 225 kPa, {2.25
: 225 kPa, {2.25 kgf/cm2}, 33 psi
90 kg (198 lbs) ~ maximum load
FRONT
REAR
as shown. A short circuit could result
from improper routing. This could cause
the engine to stop running and lights to
fail, which could result in an accident.
: 225 kPa, {2.25 kgf/cm2}, 33 psi
: 250 kPa, {2.50 kgf/cm2}, 36 psi
5BN-21668-00
1-8
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DESCRIPTION
Left view ............................................................................................. 2-1
Right view........................................................................................... 2-2
Controls and instruments ................................................................... 2-3
2
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DESCRIPTION
EAU00026
2-
Left view
2
1. Clutch fluid reservoir
2. Air filter element
3. Fuse box
4. Main fuse box
5. Owner’s tool kit
6. Shock absorber assembly spring
preload adjusting ring
7. Shock absorber assembly damping
force adjusting knob
8. Helmet holder
9. Shift pedal
10. Starter (choke) lever
(page 6-29)
(page 6-21)
(page 6-39)
(page 6-39)
(page 6-1)
(page 3-13)
2-1
(page 3-13)
(page 3-10)
(page 3-5)
(page 3-8)
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DESCRIPTION
Right view
2
11. Fuel tank cap
12. Battery
13. Coolant reservoir
14. Front brake fluid reservoir
15. Main switch
16. Radiator cap
17. Radiator
18. Engine oil filter cartridge
19. Engine oil level check window
20. Brake pedal
21. Rear brake fluid reservoir
(page 3-6)
(page 6-35)
(page 6-16)
(page 6-29)
(page 3-1)
(page 6-18)
(page 6-18)
(page 6-13)
(page 6-12)
(page 3-6)
(page 6-29)
2-2
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DESCRIPTION
Controls and instruments
2
1. Clutch lever
2. Left handlebar switches
3. Speedometer unit
4. Right handlebar switches
5. Brake lever
6. Throttle grip
7. Tachometer
8. Coolant temperature gauge
(page 3-5)
(page 3-3)
(page 3-2)
(page 3-4)
(page 3-5)
(page 6-22)
(page 3-3)
(page 3-3)
2-3
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INSTRUMENT AND CONTROL FUNCTIONS
Main switch ........................................................................................ 3-1
Indicator and warning lights ............................................................. 3-1
Speedometer unit .............................................................................. 3-2
Tachometer ....................................................................................... 3-3
Coolant temperature gauge .............................................................. 3-3
Handlebar switches ........................................................................... 3-3
Clutch lever ....................................................................................... 3-5
Shift pedal ......................................................................................... 3-5
Brake lever ........................................................................................ 3-5
Brake pedal ....................................................................................... 3-6
Fuel tank cap ..................................................................................... 3-6
Fuel ................................................................................................... 3-7
Starter (choke) lever .......................................................................... 3-8
Steering lock ..................................................................................... 3-9
Rider seat .......................................................................................... 3-9
Helmet holder .................................................................................. 3-10
Adjusting the front fork .................................................................... 3-11
Adjusting the shock absorber assemblies ....................................... 3-12
Matching the front and rear suspension settings ............................ 3-15
V-Boost ............................................................................................ 3-16
Sidestand ........................................................................................ 3-17
Ignition circuit cut-off system ........................................................... 3-17
3
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INSTRUMENT AND CONTROL FUNCTIONS
EAU00027
3-
3
EAU00028
Main switch
The main switch controls the ignition
and lighting systems. The various main
switch positions are described below.
EAU00032
ON
All electrical systems are supplied with
power, and the headlight, meter lighting, taillight and position lights come
on, and the engine can be started. The
key cannot be removed.
1. Push.
2. Release.
3. Turn.
EAU00051
P (Parking)
The meter lighting, taillight and position
lights are on, but all other electrical systems are off. The key can be removed.
The key must be pushed in from the
“OFF” position to be turned to “P”.
ECA00043
CAUTION:
Do not use the parking position for
an extended length of time, otherwise the battery may discharge.
1.
2.
3.
4.
5.
Neutral indicator light “NEUTRAL”
Turn signal indicator light “TURN”
Fuel level warning light “FUEL”
High beam indicator light “HIGH BEAM”
Oil level warning light “OIL LEVEL”
EAU03034
Indicator and warning lights
EAU00062
Neutral indicator light “NEUTRAL”
This indicator light comes on when the
transmission is in the neutral position.
_
_
EAU00038
OFF
All electrical systems are off. The key
can be removed.
3-1
EAU00059
Turn signal indicator light “TURN”
This indicator light flashes when the
turn signal switch is pushed to the left
or right.
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INSTRUMENT AND CONTROL FUNCTIONS
EAU04166
EAU04167
Fuel level warning light “FUEL”
This warning light comes on when the
fuel level drops below approximately
3 L (0.7 Imp gal, 0.8 US gal). When this
occurs, set the fuel reserve switch to
the “RES” position and refuel as soon
as possible.
The electrical circuit of the warning light
can be checked according to the following procedure.
1. Set the engine stop switch to
“RUN” and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on, have a
Yamaha dealer check the electrical circuit.
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 following procedure.
1. Set the engine stop switch to
“RUN” and turn the key to “ON”.
2. Shift the transmission into the neutral position or pull the clutch lever.
3. Push the start switch. If the warning light does not come on, have a
Yamaha dealer check the electrical circuit.
EAU00064
High beam indicator light
“HIGH BEAM”
This indicator light comes on when the
high beam of the headlight is switched
on.
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 malfunction.
_
3-2
3
1. Tripmeter reset knob
2. Odometer
3. Tripmeter
EAU00095
Speedometer unit
The speedometer unit is equipped with
a speedometer, an odometer and a
tripmeter. The speedometer shows
riding speed. The odometer shows the
total distance traveled. The tripmeter
shows the distance traveled since it
was last set to zero with the reset knob.
The tripmeter can be used to estimate
the distance that can be traveled with a
full tank of fuel. This information will enable you to plan future fuel stops.
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INSTRUMENT AND CONTROL FUNCTIONS
3
1. Tachometer
2. Tachometer red zone
1. Coolant temperature gauge
2. Coolant temperature gauge red zone
EAU00101
EAU01652
Tachometer
Coolant temperature gauge
The electric tachometer allows the rider
to monitor the engine speed and keep it
within the ideal power range.
With the key in the “ON” position, the
coolant temperature gauge indicates
the temperature of the coolant. The
coolant temperature varies with changes in the weather and engine load. If
the needle reaches or enters the red
zone, stop the motorcycle and let the
engine cool. (See page 6-48 for further
instructions.)
EC000003
CAUTION:
Do not operate the engine in the
tachometer red zone.
Red zone: 8,500 r/min and above
@
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EC000002
CAUTION:
Do not operate the engine if it is
overheated.
@
@
3-3
1. Dimmer switch “LIGHTS”
2. Turn signal switch “TURN”
3. Horn switch “HORN”
EAU00118
Handlebar switches
EAU00122
Dimmer switch “LIGHTS”
Set the switch to “HI” for the high beam
and to “LO” for the low beam.
EAU01189
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 center position.
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INSTRUMENT AND CONTROL FUNCTIONS
Since this model is equipped with a
self-canceling system, the turn signal
lights will self-cancel after the motorcycle 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 center position.
NOTE:
The self-canceling system only operates when the motorcycle is moving, so
that the turn signal lights will not selfcancel while you are stopped at an intersection.
@
@
EAU00130
Horn switch “HORN”
Press this switch to sound the horn.
EAU01653
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”.
1. Engine stop switch “ENGINE STOP”
2. Fuel reserve switch “FUEL”
3. Start switch “START”
NOTE:
After switching to “RES”, approximately
3 L (0.7 Imp gal, 0.8 US gal) of fuel remain in the fuel tank.
@
EAU04822
Engine stop switch “ENGINE STOP”
Set this switch to “RUN” before starting
the engine. Set this switch to “OFF” to
stop the engine in case of an emergency, such as when the motorcycle overturns or when the throttle cable is
stuck.
@
EAU00141
Start switch “START”
Push this switch to crank the engine
with the starter.
EC000005
CAUTION:
See page 5-1 for starting instructions prior to starting the engine.
@
@
3-4
3
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INSTRUMENT AND CONTROL FUNCTIONS
3
1. Clutch lever
1. Shift pedal
1. Brake lever
EAU00152
EAU00157
EAU00158
Clutch lever
Shift pedal
Brake lever
The clutch lever is located at the left
handlebar grip. To disengage the
clutch, pull the lever toward the handlebar 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 ignition circuit cut-off system. (See page
3-17 for an explanation of the ignition
circuit cut-off system.)
The shift pedal is located on the left
side of the engine and is used in combination with the clutch lever when
shifting the gears of the 5-speed constant-mesh transmission equipped on
this motorcycle.
The brake lever is located at the right
handlebar grip. To apply the front
brake, pull the lever toward the handlebar grip.
3-5
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INSTRUMENT AND CONTROL FUNCTIONS
3
1. Brake pedal
1. Lever (× 2)
1. Unlock.
EAU00162
Brake pedal
The brake pedal is on the right side of
the motorcycle. To apply the rear
brake, press down on the brake pedal.
EAU04168
Fuel tank cap
To remove the fuel tank cap
1. Push the levers on the left and
right side of the rider seat backrest
as shown and slide the rider seat
backrest forward.
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.
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INSTRUMENT AND CONTROL FUNCTIONS
3
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 remove it.
3. Slide the rider seat backrest rearward 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.
_
EAU00185
CAUTION:
Immediately wipe off spilled fuel
with a clean, dry, soft cloth, since
fuel may deteriorate painted surfaces or plastic parts.
@
@
EAU04265
Recommended fuel:
UNLEADED GASOLINE ONLY
Fuel tank capacity:
Total amount:
15 L (3.3 Imp gal, 4.0 US gal)
Reserve amount:
3 L (0.7 Imp gal, 0.8 US gal)
1. Fuel tank filler tube
2. Fuel level
EAU03753
Fuel
Make sure that there is sufficient fuel in
the tank. Fill the fuel tank to the bottom
of the filler tube as shown.
EW000130
_
EW000024
WARNING
Make sure that the fuel tank cap is
properly installed before riding.
_
_
_
WARNING
● Do not overfill the fuel tank, otherwise it may overflow when the
fuel warms up and expands.
● Avoid spilling fuel on the hot
engine.
_
ECA00104
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.
_
_
3-7
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INSTRUMENT AND CONTROL FUNCTIONS
Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number
[(R+M)/2] of 86 or higher, or a research
octane number of 91 or higher. If
knocking (or pinging) occurs, use a
gasoline of a different brand or premium unleaded fuel. Use of unleaded fuel
will extend spark plug life and reduce
maintenance costs.
3
1. Starter (choke) lever
EAU00211
Gasohol
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol content does not exceed 10%. Gasohol
containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or vehicle performance problems.
Starter (choke) lever
Starting a cold engine requires a richer
air-fuel mixture, which is supplied by
the starter (choke).
Move the lever in direction a to turn on
the starter (choke).
Move the lever in direction b to turn off
the starter (choke).
3-8
E_5GK.book Page 9 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
To unlock the steering
1. Open the steering lock cover, and
then insert the key.
2. Push the key in, turn it 1/8 turn
counterclockwise so that it moves
out, and then release it.
3. Remove the key, and then close
the lock cover.
3
1. Steering lock
1. Lever (× 2)
EAU02934
EAU03413
Steering lock
Rider seat
To lock the steering
1. Turn the handlebar all the way to
right.
2. Open the steering lock cover, and
then insert the key.
3. Turn the key 1/8 turn counterclockwise, push it in while turning
the handlebar slightly to the left,
and then turn the key 1/8 turn
clockwise.
4. Check that the steering is locked,
remove the key, and then close
the lock cover.
To remove the rider seat
1. Release the rider seat backrest by
pushing the levers on the left and
right side as shown, and then slide
the backrest forward.
3-9
E_5GK.book Page 10 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
3
1. Bolt (× 2)
2. Screw (× 2)
2. Remove the bolts and screws, and
then pull the rider seat off.
1. Projection
2. Seat holder
1. Helmet holder
2. Unlock.
To install the rider seat
1. Insert the projection on the front of
the rider seat into the seat holder
as shown.
2. Place the rider seat in the original
position, and then tighten the bolts
and screws.
NOTE:
Make sure that the seat is properly secured before riding.
EAU00260
Helmet holder
To open the helmet holder, insert the
key into the lock, and then turn the key
as shown.
To lock the helmet holder, place it in
the original position, and then remove
the key.
EW000030
@
@
3. Return the rider seat backrest to
the original position.
WARNING
Never ride with a helmet attached to
the helmet holder, since the helmet
may hit objects, causing loss of
control and possibly an accident.
@
@
3-10
E_5GK.book Page 11 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU03414
Adjusting the front fork
This front fork is equipped with air
valves for adjusting the spring rate.
EW000035
WARNING
Always adjust both fork legs equally, otherwise poor handling and loss
of stability may result.
@
3
@
1. Air valve cap
2. Air valve
1. Air pressure gauge
3. Check the air pressure in each
fork leg with an air pressure
gauge.
Adjust the spring rate as follows.
1. Elevate the front wheel by placing
the motorcycle on the centerstand.
NOTE:
An optional air pressure gauge is available at a Yamaha dealer.
@
NOTE:
When checking and adjusting the air
pressure, there should be no weight on
the front end of the motorcycle.
@
@
2. Remove the air valve cap from
each fork leg.
3-11
@
4. To increase the spring rate and
thereby harden the suspension,
increase the air pressure with an
air pump or compressed air. To
decrease the spring rate and
thereby soften the suspension, decrease the air pressure by pushing
each valve stem down.
E_5GK.book Page 12 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
EW000040
Spring rate:
Minimum/standard (soft):
Air pressure =
40 kPa (0.4 kgf/cm2, 5.7 psi)
Maximum (hard):
Air pressure =
100 kPa (1.0 kgf/cm2, 14 psi)
WARNING
Always adjust both shock absorber
assemblies equally, otherwise poor
handling and loss of stability may
result.
@
@
3
EC000012
CAUTION:
Never exceed the maximum air pressure, otherwise the front fork oil
seals may become damaged.
1. Shock absorber assembly (× 2)
EAU01657
@
@
EWA00037
WARNING
There must be no difference in air
pressure between the left and right
fork legs, otherwise poor handling
and loss of stability may result.
@
@
5. Securely install the air valve caps.
Adjusting the shock absorber
assemblies
Both shock absorber assemblies are
equipped with a spring preload adjusting ring and a damping force adjusting
knob.
EC000015
CAUTION:
Never attempt to turn an adjusting
mechanism beyond the maximum
or minimum settings.
@
@
3-12
E_5GK.book Page 13 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
NOTE:
● Align the bottom edge of the adjusting ring with the appropriate
setting on the shock absorber.
● Use the special wrench included in
the owner’s tool kit to make this
adjustment.
@
@
3
Spring preload
To increase the spring preload and
thereby harden the suspension, turn
the adjusting ring on each shock absorber assembly in direction a. To decrease the spring preload and thereby
soften the suspension, turn the adjusting ring on each shock absorber assembly in direction b.
Spring preload:
Minimum (soft): 1
Standard: 1
Maximum (hard): 5
1. Damping force adjusting knob
2. Position indicator
Damping force
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
direction b.
NOTE:
Align the appropriate setting on the adjusting knob with the position indicator
on the shock absorber.
@
3-13
E_5GK.book Page 14 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
Damping force:
Minimum (soft): 1
Standard: 1
Maximum (hard): 4
3
3-14
E_5GK.book Page 15 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU01658
Matching the front and rear suspension settings
Use this table as a guide to match the suspension and damping adjustments of the front fork and shock absorber assembly
according to various load conditions.
CI-06E
Load condition
3
Front fork adjustment
Shock absorber assembly adjustment
Spring preload (air pressure)
Spring preload
Damping force
Rider only
40–60 kPa
(0.4–0.6 kgf/cm2,
5.7–8.5 psi)
1–2
1–2
With passenger or with
accessories and equipment
40–100 kPa
(0.4–1.0 kgf/cm2,
5.7–14 psi)
3–5
2–4
With passenger,
accessories and equipment
40–100 kPa
(0.4–1.0 kgf/cm2,
5.7–14 psi)
5
4
EC000015
CAUTION:
Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
@
@
3-15
E_5GK.book Page 16 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
The V-Boost operation can be heard
when the main switch is turned on.
EC000026
CAUTION:
If the V-Boost does not operate, ask
a Yamaha dealer to inspect it.
@
@
3
EAU00327
V-Boost
The V-Boost is a vital part of the engine
and requires very sophisticated adjustment. Adjustment should be left to a
Yamaha dealer who has the professional knowledge and experience to do
so.
EC000025
CAUTION:
The V-Boost was set at the Yamaha
factory after many tests. If the settings are changed by someone without sufficient technical knowledge,
poor engine performance and damage may result.
@
@
3-16
E_5GK.book Page 17 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
EAU00330
Sidestand
The sidestand is located on the left side
of the frame. Raise the sidestand or
lower it with your foot while holding the
motorcycle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
@
3
@
EW000044
WARNING
The motorcycle must not be ridden
with the sidestand down, or if the
sidestand 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
responsibility of raising the sidestand before starting off. Therefore,
check this system regularly as described below and have a Yamaha
dealer repair it if it does not function
properly.
@
@
EAU03741
Ignition circuit cut-off system
The ignition circuit cut-off system (comprising the sidestand switch, clutch
switch and neutral switch) has the following functions.
● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is
not pulled.
● It prevents starting when the transmission is in gear and the clutch
lever is pulled, but the sidestand is
still down.
● It cuts the running engine when
the transmission is in gear and the
sidestand is moved down.
Periodically check the operation of the
ignition circuit cut-off system according
to the following procedure.
EW000046
_
_
3-17
WARNING
● The vehicle must be placed on
the centerstand during this inspection.
● If a malfunction is noted, have a
Yamaha dealer check the system before riding.
E_5GK.book Page 18 Friday, May 31, 2002 10:59 AM
INSTRUMENT AND CONTROL FUNCTIONS
CD-01E
NOTE:
This check is most reliable if performed with
a warmed-up engine.
With the engine turned off:
1. Move the sidestand down.
2. Make sure that the engine stop switch is set to “RUN”.
3. Turn the key to “ON”.
4. Shift the transmission into the neutral position.
5. Push the start switch.
Does the engine start?
YES
NO
The neutral switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The sidestand switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
NO
The clutch switch may be defective.
The motorcycle should not be ridden until
checked by a Yamaha dealer.
With the engine still running:
6. Move the sidestand up.
7. Keep the clutch lever pulled.
8. Shift the transmission into gear.
9. Move the sidestand down.
Does the engine stall?
YES
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?
YES
The system is OK. The motorcycle can be ridden.
3-18
3
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
PRE-OPERATION CHECKS
Pre-operation check list ..................................................................... 4-1
4
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
PRE-OPERATION CHECKS
EAU01114
4-
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 inspection, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM
CHECKS
PAGE
Fuel
• Check fuel level in fuel tank.
• Refuel if necessary.
• Check fuel line for leakage.
Engine oil
• Check oil level in engine.
• If necessary, add recommended oil to specified level.
• Check vehicle for oil leakage.
Final gear oil
• Check vehicle for oil leakage.
Coolant
• Check coolant level in reservoir.
• If necessary, add recommended coolant to specified level.
• Check cooling system for leakage.
6-16–6-17
Front brake
•
•
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check lever free play.
Adjust if necessary.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-27–6-30
Rear brake
•
•
•
•
•
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended brake fluid to specified level.
Check hydraulic system for leakage.
6-27–6-30
4
3-7–3-8
6-11–6-12
6-15
4-1
E_5GK.book Page 2 Friday, May 31, 2002 10:59 AM
PRE-OPERATION CHECKS
ITEM
CHECKS
Check operation.
If soft or spongy, have Yamaha dealer bleed hydraulic system.
Check fluid level in reservoir.
If necessary, add recommended fluid to specified level.
Check hydraulic system for leakage.
PAGE
Clutch
•
•
•
•
•
Throttle grip
• Make sure that operation is smooth.
• Check cable free play.
• If necessary, have Yamaha dealer adjust cable free play and lubricate cable and
grip housing.
Control cables
• Make sure that operation is smooth.
• Lubricate if necessary.
Wheels and tires
•
•
•
•
Brake and shift pedals
• Make sure that operation is smooth.
• Lubricate pedal pivoting points if necessary.
6-31
Brake and clutch levers
• Make sure that operation is smooth.
• Lubricate lever pivoting points if necessary.
6-32
Centerstand, sidestand
• Make sure that operation is smooth.
• Lubricate pivots if necessary.
6-32
Chassis fasteners
• Make sure that all nuts, bolts and screws are properly tightened.
• Tighten if necessary.
—
Instruments, lights, signals
and switches
• Check operation.
• Correct if necessary.
—
Sidestand switch
• Check operation of ignition circuit cut-off system.
• If system is defective, have Yamaha dealer check vehicle.
Battery
• Check fluid level.
• Fill with distilled water if necessary.
6-26, 6-29–6-30
6-22, 6-31
6-30
Check for damage.
Check tire condition and tread depth.
Check air pressure.
Correct if necessary.
4
6-23–6-25
3-17
6-35–6-38
4-2
E_5GK.book Page 3 Friday, May 31, 2002 10:59 AM
PRE-OPERATION CHECKS
NOTE:
Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very
short time; and the added safety it assures is more than worth the time involved.
_
_
EWA00033
WARNING
If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating
the motorcycle.
_
_
4
4-3
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
OPERATION AND IMPORTANT RIDING POINTS
Starting and warming up a cold engine ............................................. 5-1
Starting a warm engine ..................................................................... 5-3
Shifting .............................................................................................. 5-3
Engine break-in ................................................................................. 5-5
Parking .............................................................................................. 5-6
5
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU00372
5-
@
5
EAU00373
EAU00376
WARNING
● Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer regarding any control or function
that you do not thoroughly understand.
● Never start the engine or operate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of consciousness and death within a
short time. Always make sure
that there is adequate ventilation.
● Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised completely, it could contact the
ground and distract the operator, resulting in a possible loss
of control.
CAUTION:
● Make sure not to store personal
items near the air cleaner intake, otherwise air intake will be
blocked and performance will
suffer.
● Make sure not to put anything
near the battery and its terminals, otherwise electrical failure
and acid corrosion may result.
@
EAU04700
Starting and warming up a
cold engine
In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:
● The transmission is in the neutral
position.
● The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
@
_
WARNING
Before starting the engine,
check the function of the ignition circuit cut-off system according to the procedure
described on page 3-18.
● Never ride with the sidestand
down.
●
_
1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “RUN”.
@
5-1
E_5GK.book Page 2 Friday, May 31, 2002 10:59 AM
OPERATION AND IMPORTANT RIDING POINTS
EC000035
not go off after starting with sufficient engine oil, have a
Yamaha dealer check the electrical circuit.
● If the fuel level warning light remains 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 after starting with sufficient fuel,
have a Yamaha dealer check the
electrical circuit.
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 preserve the battery. Do not crank the engine more than 10 seconds on any one
attempt.
_
CAUTION:
If the fuel level warning light comes
on, check the fuel level, and, if necessary, refuel as soon as possible.
_
_
2. Shift the transmission into the neutral 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 circuit.
_
EC000038
_
_
3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-8 for starter (choke) operation.)
4. Start the engine by pushing the
start switch.
_
CAUTION:
● 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 released.
● If the oil level warning light flickers or remains on after starting,
immediately stop the engine,
and then check the engine oil
level and the vehicle for oil leakage. If necessary, add engine
oil, and then check the warning
light again. If the warning light
does not come on when pushing the start switch, or if it does
5-2
_
5. After starting the engine, move the
starter (choke) back halfway.
ECA00055
CAUTION:
For maximum engine life, always
warm the engine up before starting
off. Never accelerate hard when the
engine is cold!
_
_
5
E_5GK.book Page 3 Friday, May 31, 2002 10:59 AM
OPERATION AND IMPORTANT RIDING POINTS
6. When the engine is warm, turn the
starter (choke) off.
NOTE:
The engine is warm when it responds
normally to the throttle with the starter
(choke) turned off. To avoid the possibility of excessive exhaust emissions,
never leave the starter (choke) on longer than necessary. The time necessary
for starter (choke) use depends upon
the ambient temperature. Temperatures above 10 °C (50 °F) require about
7 seconds of starter (choke) use and
temperatures below 10 °C (50 °F) require about 35 seconds with the starter
(choke) turned on, then about 2.5 minutes with the starter (choke) in the halfway position.
_
5
EAU01258
Starting a warm engine
Follow the same procedure as for starting a cold engine with the exception
that the starter (choke) is not required
when the engine is warm.
1. Shift pedal
N. Neutral position
EAU00423
Shifting
Shifting gears lets you control the
amount of engine power available for
starting off, accelerating, climbing hills,
etc.
The gear positions are shown in the illustration.
_
NOTE:
To shift the transmission into the neutral position, press the shift pedal down
repeatedly until it reaches the end of its
travel, and then slightly raise it.
@
@
5-3
E_5GK.book Page 4 Friday, May 31, 2002 10:59 AM
OPERATION AND IMPORTANT RIDING POINTS
EC000048
@
@
CAUTION:
● 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 distances. The transmission is
properly lubricated only when
the engine is running. Inadequate lubrication may damage
the transmission.
● Always use the clutch while
changing gears to avoid damaging the engine, transmission,
and drive train, which are not
designed to withstand the
shock of forced shifting.
EAU02988
EAU00427
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 table on page 5-5,
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 position.)
6. Open the throttle part way and
gradually release the clutch lever.
7. Follow the same procedure when
shifting to the next higher gear.
To decelerate
1. Apply both the front and the rear
brakes to slow the motorcycle.
2. Shift the transmission into first
gear when the motorcycle reaches
20 km/h (12.5 mi/h). If the engine
is about to stall or runs very roughly, pull the clutch lever in and use
the brakes to stop the motorcycle.
3. Shift the transmission into the neutral position when the motorcycle
is almost completely stopped. The
neutral indicator light should come
on.
NOTE:
Always shift gears at the recommended shift points.
@
@
5-4
5
E_5GK.book Page 5 Friday, May 31, 2002 10:59 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU01128
EAU02974
Recommended shift points
The recommended shift points during
acceleration and deceleration are
shown in the table below.
CF-04E
1st
2nd
3rd
4th
5
→
→
→
→
2nd
3rd
4th
5th
Acceleration
shift point
km/h (mi/h)
Deceleration
shift point
km/h (mi/h)
16 (10.0)
24 (15.0)
32 (20.0)
40 (25.0)
20 (12.5)
20 (12.5)
20 (12.5)
20 (12.5)
Engine break-in
There is never a more important period
in the life of your engine than the period
between 0 and 1,600 km (1,000 mi).
For this reason, you should read the
following material carefully.
Since the engine is brand new, do not
put an excessive load on it for the first
1,600 km (1,000 mi). The various parts
in the engine wear and polish themselves to the correct operating clearances. During this period, prolonged
full-throttle operation or any condition
that might result in engine overheating
must be avoided.
EAU04032*
0–1,000 km (0–600 mi)
Avoid prolonged operation
4,500 r/min.
above
1,000–1,600 km (600–1,000 mi)
Avoid prolonged operation above
5,500 r/min.
EC000056*
CAUTION:
After 1,000 km (600 mi) of operation,
the engine oil and final gear oil must
be changed, and the oil filter cartridge replaced.
_
_
1,600 km (1,000 mi) and beyond
The vehicle can now be operated normally.
EC000053
_
_
5-5
CAUTION:
● Keep the engine speed out of
the tachometer red zone.
● If any engine trouble should occur during the engine break-in
period, immediately have a
Yamaha dealer check the vehicle.
E_5GK.book Page 6 Friday, May 31, 2002 10:59 AM
OPERATION AND IMPORTANT RIDING POINTS
EAU00460
Parking
When parking, stop the engine, and
then remove the key from the main
switch.
EW000058
@
WARNING
Since the engine and exhaust
system can become very hot,
park in a place where pedestrians or children are not likely to
touch them.
● Do not park on a slope or on
soft ground, otherwise the
motorcycle may overturn.
●
5
@
5-6
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Periodic maintenance ..........................................6-1
Owner’s tool kit ....................................................6-1
Periodic maintenance chart for emission
control system ...................................................6-3
General maintenance and lubrication chart .........6-5
Removing and installing the cowling and
panels ................................................................6-8
Checking the spark plugs ....................................6-9
Canister (for California only) ..............................6-11
Engine oil and oil filter cartridge ........................6-11
Final gear oil ......................................................6-15
Coolant ..............................................................6-16
Cleaning the air filter element ............................6-21
Adjusting the carburetors ...................................6-22
Adjusting the throttle cable free play ..................6-22
Adjusting the valve clearance ............................6-22
Tires ...................................................................6-23
Cast wheels .......................................................6-25
Accessories and replacement parts ..................6-25
Clutch lever free play .........................................6-26
Adjusting the brake lever free play .....................6-27
Adjusting the brake pedal position .....................6-27
Adjusting the rear brake light switch ..................6-28
Checking the front and rear brake pads .............6-28
Checking the brake and clutch fluid levels ........ 6-29
Changing the brake and clutch fluids ................ 6-30
Checking and lubricating the cables ................. 6-30
Checking and lubricating the throttle grip and
cable ............................................................... 6-31
Checking and lubricating the brake and
shift pedals ...................................................... 6-31
Checking and lubricating the brake and
clutch levers .................................................... 6-32
Checking and lubricating the centerstand and
sidestand ......................................................... 6-32
Lubricating the rear suspension ........................ 6-33
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-34
Checking the wheel bearings ............................ 6-35
Battery ............................................................... 6-35
Replacing the fuses .......................................... 6-39
Replacing the headlight bulb ............................. 6-40
Replacing a turn signal light bulb or
the tail/brake light bulb .................................... 6-41
Front wheel ....................................................... 6-42
Rear wheel ........................................................ 6-44
Troubleshooting ................................................. 6-46
Troubleshooting charts ...................................... 6-47
6
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00462
6-
EAU01790
Safety is an obligation of the owner.
Periodic inspection, adjustment and lubrication will keep your vehicle in the
safest and most efficient condition possible. The most important points of
motorcycle inspection, adjustment, and
lubrication are explained on the following pages.
Maintenance, replacement, or repair
of the emission control devices and
systems may be performed by any
repair establishment or individual
that is certified (if applicable).
EW000060
6
WARNING
If you are not familiar with motorcycle maintenance work, have a
Yamaha dealer do it for you.
@
@
EAU00467
PERIODIC MAINTENANCE
PROPER PERIODIC MAINTENANCE
OF YOUR MOTORCYCLE IS IMPORTANT IN ORDER TO ENJOY LONG,
PLEASURABLE SERVICE. ESPECIALLY IMPORTANT ARE THE
MAINTENANCE SERVICES RELATED TO EMISSIONS CONTROL.
THESE CONTROLS NOT ONLY
FUNCTION TO ENSURE CLEANER
AIR, BUT ARE ALSO VITAL TO
PROPER ENGINE OPERATION AND
MAXIMUM PERFORMANCE. IN THE
FOLLOWING PERIODIC MAINTENANCE CHARTS, THE SERVICES
RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY. THESE SERVICES REQUIRE
SPECIALIZED DATA, KNOWLEDGE,
AND EQUIPMENT. YAMAHA DEALERS ARE TRAINED AND EQUIPPED
TO PERFORM THESE PARTICULAR
SERVICES.
6-1
1. Owner’s tool kit
2. Rider seat backrest
EAU04823
Owner’s tool kit
The tool kit is located inside the storage
compartment behind the rider seat
backrest. (See page 3-9 for an explanation on moving the rider seat backrest forward and back.)
E_5GK.book Page 2 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000062
WARNING
Modifications not approved by
Yamaha may cause loss of performance, excessive emissions, and
render the vehicle unsafe for use.
Consult a Yamaha dealer before attempting any changes.
_
_
The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. However, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.
6
NOTE:
If you do not have the tools or experience required for a particular job, have
a Yamaha dealer perform it for you.
_
_
6-2
E_5GK.book Page 3 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00471
Periodic maintenance chart for emission control system
INITIAL
No.
ITEM
1 * Valve clearance
6
ROUTINE
ODOMETER READINGS
20,000 mi
16,000 mi
12,000 mi
8,000 mi
4,000mi
600 mi
(1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
or
6 months 12 months 18 months 24 months 30 months
1 month
• Check and adjust valve clearance
when engine is cold.
Every 30,000 mi (42,000 km) or 42 months
2
Spark plugs
• Check condition.
• Adjust gap and clean.
• Replace every 8,000 mi (13,000 km)
or 12 months.
√
Replace.
√
Replace.
√
3 *
Crankcase
ventilation system
• Check ventilation hose for cracks or
damage.
• Replace if necessary.
√
√
√
√
√
4 * Fuel line
• Check fuel hoses for cracks or
damage.
• Replace if necessary.
√
√
√
√
√
5 * Fuel filter
• Replace every 20,000 mi (31,000 km)
or 30 months.
6 * Exhaust system
• Check for leakage.
• Tighten if necessary.
• Replace gasket(s) if necessary.
7 *
Carburetor
synchronization
8 * Idle speed
• Adjust synchronization of carburetors.
Replace.
√
• Check and adjust engine idle speed.
• Adjust cable free play.
6-3
√
√
√
√
√
√
√
√
√
√
√
√
√
√
√
E_5GK.book Page 4 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
No.
9 *
ITEM
Evaporative
emission control
system (For
California only)
ROUTINE
INITIAL
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
20,000 mi
16,000 mi
12,000 mi
8,000 mi
4,000mi
(7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
or
6 months 12 months 18 months 24 months 30 months
• Check control system for damage.
• Replace if necessary.
√
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
6
6-4
E_5GK.book Page 5 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00472
General maintenance and lubrication chart
INITIAL
No.
6
ITEM
ROUTINE
TYPE
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000 mi
(7,000 km)
or
6 months
√
√
8,000 mi
12,000 mi
16,000 mi
20,000 mi
(13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
12 months 18 months 24 months 30 months
1
Engine oil
• Replace (warm up
engine before
draining).
2
Engine oil filter
cartridge
• Replace.
–
3 *
Air filter element
• Clean with
compressed air.
• Replace if necessary.
–
√
√
√
√
√
• Check hose for cracks
or damage, replace if
necessary.
–
√
√
√
√
√
4 *
Cooling system
See page 8-1.
√
√
√
√
√
√
√
High-quality ethylene
• Replace every
glycol antifreeze
16,000 mi (25,000 km) containg corrosin
inhibitors for aluminum
or 24 months.
engine
Replace.
5 *
Brake system
• Adjust free play.
• Replace pads if
necessary.
–
√
√
√
√
√
√
6 *
Clutch
• Check operation and
fluid leakage.
(See NOTE page 6-7.)
• Correct if necessary.
–
√
√
√
√
√
√
Final gear oil
• Check oil level and
leakage.
Hypoid gear oil SAE 80
• Replace every
(API GL-4)
16,000 mi (25,000 km)
or 24 months.
Replace.
√
√
√
Replace.
√
7
6-5
E_5GK.book Page 6 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
ITEM
ROUTINE
TYPE
ODOMETER READINGS
600 mi
(1,000 km)
or
1 month
4,000 mi
(7,000 km)
or
6 months
√
√
8,000 mi
12,000 mi
16,000 mi
(13,000 km) (19,000 km) (25,000 km)
or
or
or
12 months 18 months 24 months
20,000 mi
(31,000 km)
or
30 months
Control and meter
cables
• Apply chain lube
thoroughly.
Yamaha Chain and
Cable Lube or engine oil
SAE 10W-30 (API SE)
9 *
Swingarm pivot
bearing
• Check bearing
assembly for
looseness.
• Moderately repack
every 16,000 mi
(25,000 km) or
24 months.
Lithium-soap-based
grease
10
Brake and clutch
lever pivot shaft
• Apply lithium-soapbased grease
(all-purpose grease)
lightly.
Lithium-soap-based
grease
(all-purpose grease)
√
√
√
√
√
11
Brake pedal and shift
pedal shaft
• Lubricate.
• Apply lithium-soapbased grease
(all-purpose grease)
lightly.
Lithium-soap-based
grease
(all-purpose grease)
√
√
√
√
√
12 *
Center/sidestand
pivots
• Check operation and
lubricate.
• Apply lithium-soapbased grease
(all-purpose grease)
lightly.
Lithium-soap-based
grease
(all-purpose grease)
√
√
√
√
√
13 *
Front fork
• Check operation and
leakage.
√
√
√
√
√
Steering bearings
• Check bearing
assembly for
looseness.
• Moderately repack
every 16,000 mi
(25,000 km) or
24 months.
√
√
√
Repack.
√
8
14 *
√
√
√
–
Lithium-soap-based
grease
6-6
√
√
Repack.
6
E_5GK.book Page 7 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
INITIAL
No.
ITEM
ROUTINE
TYPE
600 mi
(1,000 km)
or
1 month
ODOMETER READINGS
4,000 mi
(7,000 km)
or
6 months
8,000 mi
12,000 mi
16,000 mi
20,000 mi
(13,000 km) (19,000 km) (25,000 km) (31,000 km)
or
or
or
or
12 months 18 months 24 months 30 months
Wheel bearings
• Check bearings for
smooth rotation.
–
√
√
√
√
√
16 *
Battery
• Check specific gravity
and breather pipe for
proper operation.
–
√
√
√
√
√
17 *
Sidestand switch
• Check and clean or
replace if necessary.
–
√
√
√
√
√
15 *
√
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
EAU03907
NOTE:
From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
_
_
EAU03892
6
NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake and clutch systems
• After disassembling the brake or clutch master cylinders, caliper cylinders or clutch release cylinder, always change
the fluid. Regularly check the brake and clutch fluid levels and fill the reservoirs as required.
• Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and clutch release
cylinder every two years.
• Replace the brake and clutch hoses every four years or if cracked or damaged.
_
_
6-7
E_5GK.book Page 8 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Cowling A
2. Panel A
3. Panel B
1. Unlock.
EAU03415
EAU03516
Removing and installing the
cowling and panels
The cowling and panels shown above
need to be removed to perform some
of the maintenance jobs described in
this chapter. Refer to this section each
time the cowling or a panel needs to be
removed and installed.
Cowling A
To remove the cowling
1. Insert the key into the lock, and
then turn it clockwise.
2. Pull the cowling off as shown.
6-8
1. Holder (× 2)
2. Projection (× 2)
To install the cowling
1. Align the holders under the cowling with the projections on the
frame.
2. Push down on the rear of the cowling until it locks in place.
3. Remove the key from the lock.
6
E_5GK.book Page 9 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (× 2)
6
1. Screw (× 2)
1. Spark plug cap
EAU03340
EAU01315
Panel A
To remove the panel
1. Remove cowling A. (See page 6-8
for cowling removal and installation procedures.)
2. Remove the screws, and then take
the panel off.
Panel B
To remove the panel
Remove the screws, and then take the
panel off.
To install the panel
Place the panel in the original position,
and then install the screws.
To install the panel
1. Place the panel in the original position, and then install the screws.
2. Install the cowling.
EAU03329
Checking the spark plugs
The spark plugs are important engine
components, which are easy to check.
Since heat and deposits will cause any
spark plug to slowly erode, the spark
plugs should be removed and checked
in accordance with the periodic maintenance and lubrication chart. In addition,
the condition of the spark plugs can reveal the condition of the engine.
To remove a spark plug
1. Remove the spark plug cap.
6-9
E_5GK.book Page 10 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
If any spark plug shows a distinctly different color, the engine could be defective. Do not attempt to diagnose such
problems yourself. Instead, have a
Yamaha dealer check the motorcycle.
@
@
1. Spark plug wrench
2. Remove the spark plug as shown,
with the spark plug wrench included in the owner’s tool kit.
To check the spark plugs
1. Check that the porcelain insulator
around the center electrode on
each spark plug is a medium-tolight tan (the ideal color when the
motorcycle is ridden normally).
2. Check that all spark plugs installed
in the engine have the same color.
3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace
it if necessary.
Specified spark plug:
DPR8EA-9/NGK or
X24EPR-U9/DENSO
a. Spark plug gap
To install a spark plug
1. Measure the spark plug gap with a
wire thickness gauge and, if necessary, adjust the gap to specification.
Spark plug gap:
0.8–0.9 mm (0.03–0.04 in)
2. Clean the surface of the spark
plug gasket and its mating surface, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then tighten it to the specified torque.
6-10
6
E_5GK.book Page 11 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04623
Engine oil and oil filter
cartridge
Tightening torque:
Spark plug:
18 Nm (1.8 m·kgf, 13 ft·lbf)
The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and
lubrication chart.
NOTE:
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the specified torque as soon as possible.
@
To check the engine oil level
1. Place the motorcycle on the centerstand.
@
4. Install the spark plug cap.
6
NOTE:
Make sure that the motorcycle is positioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading.
_
EAU01796
Canister (for California only)
This model is equipped with a canister
to prevent the discharging of fuel vapor
into the atmosphere.
● Check each hose connection.
● Check each hose and canister for
cracks or damage. Replace if
damaged.
● Make sure the vent hose is not
blocked. Clean it if necessary.
6-11
_
2. Start the engine, warm it up for
several minutes, and then turn it
off.
E_5GK.book Page 12 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Engine oil level check window
2. Maximum level mark
3. Minimum level mark
3. Wait a few minutes until the oil settles, and then check the oil level
through the check window located
at the bottom-right side of the
crankcase.
NOTE:
The engine oil should be between the
minimum and maximum level marks.
1. Engine oil filler cap
1. Engine oil drain bolt
To change the engine oil (with or
without oil filter cartridge replacement)
1. Start the engine, warm it up for
several minutes, and then turn it
off.
2. Place an oil pan under the engine
to collect the used oil.
_
_
4. If the engine oil is below the minimum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
6-12
3. Remove the engine oil filler cap
and drain bolt to drain the oil from
the crankcase.
NOTE:
Skip steps 4–6 if the oil filter cartridge is
not being replaced.
_
_
6
E_5GK.book Page 13 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Oil filter cartridge
2. Oil filter wrench
6
1. O-ring
1. Torque wrench
4. Remove the oil filter cartridge with
an oil filter wrench.
5. Apply a thin coat of engine oil to
the O-ring of the new oil filter cartridge.
NOTE:
An oil filter wrench is available at a
Yamaha dealer.
NOTE:
Make sure that the O-ring is properly
seated.
_
6. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
_
_
_
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf, 12 ft·lbf)
7. Install the engine oil drain bolt, and
then tighten it to the specified
torque.
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
6-13
E_5GK.book Page 14 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
8. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
3.2 L (2.82 Imp qt, 3.38 US qt)
With oil filter cartridge
replacement:
3.4 L (2.99 Imp qt, 3.59 US qt)
Total amount (dry engine):
4 L (3.52 Imp qt, 4.23 US qt)
_
ECA00133
EC000067
CAUTION:
● In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not
mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In
addition, do not use oils labeled
“ENERGY CONSERVING II” or
higher.
● Make sure that no foreign material enters the crankcase.
CAUTION:
If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha dealer check the vehicle.
_
9. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.
NOTE:
After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient.
_
_
6-14
_
_
10. Turn the engine off, and then
check the oil level and correct it if
necessary.
6
E_5GK.book Page 15 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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.
EAU03681
Final gear oil
The final gear case must be checked
for oil leakage before each ride. If any
leakage is found, have a Yamaha dealer check and repair the motorcycle. In
addition, the final gear oil must be
changed as follows at the intervals
specified in the periodic maintenance
and lubrication chart.
EW000066
_
WARNING
Make sure that no foreign material enters the final gear case.
● Make sure that no oil gets on
the tire or wheel.
1. Final gear oil filler bolt
2. Correct oil level
3. Final gear oil drain bolt
●
6
_
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.
2. Remove the oil filler bolt, and then
check the oil level in the final gear
case.
Recommended final gear oil:
Hypoid gear oil SAE 80 (API GL4)
or multi-grade hypoid gear oil
SAE 80W-90
Oil quantity:
0.2 L (0.18 Imp qt, 0.21 US qt)
NOTE:
The oil level should be at the brim of
the filler hole.
_
To check the final gear oil level
1. Place the motorcycle on the centerstand.
NOTE:
● The final gear oil level must be
checked on a cold engine.
● Make sure that the motorcycle is
positioned straight up when checking the oil level. A slight tilt to the
side can result in a false reading.
_
_
_
3. If the oil is below the brim of the filler hole, add sufficient oil of the recommended type to raise it to the
correct level.
NOTE:
GL4 is a quality rating. Hypoid gear oils
rated GL5 or GL6 may also be used.
_
_
To change the final gear oil
1. Place an oil pan under the final
gear case to collect the used oil.
6-15
5. Install and tighten the filler bolt.
6. Check the final gear case for oil
leakage. If oil is leaking, check for
the cause.
E_5GK.book Page 16 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04868
Coolant
Coolant reservoir capacity
(up to the maximum level mark):
0.3 L (0.26 Imp, 0.32 US qt)
The coolant level should be checked
before each ride. In addition, the coolant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
To check the coolant level
1. Place the motorcycle on the centerstand and hold it in an upright
position.
2. Remove cowling A. (See page 6-8
for cowling removal and installation procedures.)
NOTE:
● The coolant level must be checked
on a cold engine since the level
varies with engine temperature.
● Make sure that the motorcycle is
positioned straight up when
checking the coolant level. A slight
tilt to the side can result in a false
reading.
1. Maximum level mark
2. Minimum level mark
3. Check the coolant level in the
coolant reservoir.
NOTE:
The coolant should be between the
minimum and maximum level marks.
_
_
_
4. If the coolant is at or below the
minimum level mark, remove the
coolant reservoir cap and add
coolant to the maximum level
mark.
5. Install the coolant reservoir cap
and the cowling.
_
6-16
6
E_5GK.book Page 17 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000080
NOTE:
● The radiator fan is automatically
switched on or off according to the
coolant temperature in the radiator.
● If the engine overheats, see
page 6-48 for further instructions.
_
_
6
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 coolant as soon as possible, otherwise the engine may not be
sufficiently cooled and the cooling 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.
_
_
EW000067
WARNING
Never attempt to remove the radiator cap when the engine is hot.
_
_
6-17
EAU04865
To change the coolant
1. Place the motorcycle on the centerstand and let the engine cool if
necessary.
2. Remove cowling A and panel A.
(See pages 6-8 and 6-9 for cowling and panel removal and installation procedures.)
3. Place a container under the engine to collect the used coolant.
E_5GK.book Page 18 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Radiator cap
1. Coolant drain cock
2. Position indicator
4. Remove the radiator cap.
EW000067
WARNING
Never attempt to remove the radiator cap when the engine is hot.
1. Water pump drain bolt
5. Turn the coolant drain cock to
“ON”.
6. Remove the water pump drain bolt
to drain the water pump housing.
_
6
_
6-18
E_5GK.book Page 19 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Tightening torque:
Water pump drain bolt:
43 Nm (4.3 m·kgf, 31 ft·lbf)
11. Install the rubber coolant drain
plugs, and then install the cylinder
drain plug covers.
1. Screw (× 4)
7. Remove the cylinder drain plug
covers on the outside of the cylinder blocks by removing the
screws.
6
1. Rubber coolant drain plug (× 4)
8. Remove the rubber coolant drain
plugs to drain the coolant from the
engine.
9. After the coolant is completely
drained, thoroughly flush the cooling system with clean tap water.
10. Install the water pump drain bolt,
and then tighten it to the specified
torque.
NOTE:
Check the washer for damage and replace it if necessary.
_
_
6-19
NOTE:
Check the rubber plugs for damage
and replace them if necessary.
_
_
12. Turn the coolant drain cock to
“OFF”.
13. Pour the recommended coolant
into the reservoir to the maximum
level, and then install the cap.
14. Pour the recommended coolant
into the radiator until it is full.
E_5GK.book Page 20 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Antifreeze/water mixture ratio:
1:1
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Coolant quantity:
Total amount:
3.05 L (2.68 Imp qt, 3.22 US qt)
Coolant reservoir capacity
(up to the maximum level mark):
0.3 L (0.26 Imp qt, 0.32 US qt)
EC000080
_
CAUTION:
● 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 coolant as soon as possible, otherwise the engine may not be
sufficiently cooled and the cooling 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.
_
15. Install the radiator cap, start the
engine, let it idle for several minutes, and then turn it off.
16. Remove the radiator cap to check
the coolant level in the radiator. If
necessary, add sufficient coolant
until it reaches the top of the radiator, and then install the radiator
cap.
17. Check the coolant level in the reservoir. If necessary, remove the
coolant reservoir cap, add coolant
to the maximum level mark, and
then install the cap.
18. Start the engine, and then check
the vehicle for coolant leakage. If
coolant is leaking, have a Yamaha
dealer check the cooling system.
19. Install the cowling and the panel.
6-20
6
E_5GK.book Page 21 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000082*
@
1. Screw (× 6)
1. Air filter element
EAU01662*
Cleaning the air filter element
6
The air filter element should be cleaned
at the intervals specified in the periodic
maintenance and lubrication chart.
Clean the air filter element more frequently if you are riding in unusually
wet or dusty areas.
1. Remove cowling A. (See page 6-8
for cowling removal and installation procedures.)
2. Remove the air filter case cover by
removing the screws.
3. Pull the air filter element out.
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.
6-21
CAUTION:
● Make sure that the air filter element is properly seated in the
air filter case.
● The engine should never be operated without the air filter element installed, otherwise the
pistons and/or cylinders may
become excessively worn.
@
6. Install the air filter case cover by
installing the screws.
7. Install the cowling.
E_5GK.book Page 22 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00628
EAU00637
Adjusting the carburetors
Adjusting the valve clearance
The carburetors are important parts of
the engine and emission control system, which require very sophisticated
adjustment. Therefore, all carburetor
adjustments should be left to a
Yamaha dealer, who has the necessary professional knowledge and experience.
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.
a. Throttle cable free play
EAU00635
Adjusting the throttle cable
free play
The throttle cable free play should
measure 3–5 mm (0.12–0.20 in) at the
throttle grip. Periodically check the
throttle cable free play and, if necessary, have a Yamaha dealer adjust it.
6-22
6
E_5GK.book Page 23 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03360
CE-22E
Tires
To maximize the performance, durability, and safe operation of your motorcycle, 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.
EW000082
@
6
WARNING
● The tire air pressure must be
checked and adjusted on cold
tires (i.e., when the temperature
of the tires equals the ambient
temperature).
● The tire air pressure must be
adjusted in accordance with the
riding speed and with the total
weight of rider, passenger, cargo, and accessories approved
for this model.
EW000083
Tire air pressure
(measured on cold tires)
WARNING
Proper loading of your motorcycle
is important for several characteristics of your motorcycle, such as
handling, braking, performance and
safety. Do not carry loosely packed
items that can shift. Securely pack
your heaviest items close to the
center of the motorcycle, and distribute the weight evenly from side
to side. Properly adjust the suspension for your load, and check the
condition and pressure of your tires.
NEVER OVERLOAD YOUR MOTORCYCLE. Make sure the total weight
of the cargo, rider, passenger, and
accessories (cowling, saddlebags,
etc. if approved for this model) does
not exceed the maximum load of the
motorcycle. Operation of an overloaded motorcycle could cause tire
damage, an accident, or even injury.
@
Load*
Front
Rear
Up to 90 kg (198 lb)
225 kPa
225 kPa
(2.25 kgf/cm2, (2.25 kgf/cm2,
33 psi)
33 psi)
90 kg (198 lb)–
maximum
225 kPa
250 kPa
(2.25 kgf/cm2, (2.50 kgf/cm2,
33 psi)
36 psi)
High-speed riding
225 kPa
250 kPa
(2.25 kgf/cm2, (2.50 kgf/cm2,
33 psi)
36 psi)
CE-07E
Maximum load*
216 kg (476 lb): VMX12
215 kg (474 lb): VMX12C
* Total weight of rider, passenger, cargo and
accessories
@
@
6-23
E_5GK.book Page 24 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
CE-10E
FRONT
Manufacturer
EAU00684
Size
Model
WARNING
This motorcycle is fitted with superhigh-speed tires. Note the following
points in order to make the most efficient use of these tires.
● Use only the specified replacement tires. Other tires may run
the danger of bursting at super
high speeds.
● Brand-new tires can have a relatively poor grip on certain road
surfaces until they have been
“broken in”. Therefore, it is advisable before doing any highspeed riding to ride conservatively for approximately 100 km
(60 mi) after installing a new
tire.
● The tires must be warmed up
before a high-speed run.
● Always adjust the tire air pressure according to the operating
conditions.
@
Bridgestone
Dunlop
110/90-18 M/C 61V
110/90-18 61V
110/90-18 M/C 61V
110/90-18 61V
G525AW
F20
REAR
1. Tire sidewall
2. Tire wear indicator
a. Tire tread depth
Tire inspection
Always check the tires before operating
the motorcycle. If a tire tread shows
crosswise lines (minimum tread depth),
if the tire has a nail or glass fragments
in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and
have the tire replaced.
Manufacturer
Size
Model
Bridgestone
150/90-15 M/C 74V
G526BW
Dunlop
150/90-15 M/C 74V
K525
CE-23E
Minimum tire tread depth
(front and rear)
1.0 mm (0.04 in)
@
6-24
6
E_5GK.book Page 25 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00689
Cast wheels
6
To maximize the performance, durability, and safe operation of your motorcycle, 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 handling characteristics, and a shortened tire life.
● Ride at moderate speeds after
changing a tire since the tire surface must first be “broken in” for it
to develop its optimal characteristics.
●
After repairing or replacing a tire,
tighten the valve stem nut and
locknut to the specified torques.
EAU00691
Accessories and replacement
parts
EW000098
Tightening torques:
Valve stem nut:
1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
Valve stem locknut:
1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
6-25
WARNING
This motorcycle is not designed to
pull a trailer or to be attached to a
sidecar. The accessories or replacement parts you choose for your
motorcycle should be designed specifically for this model, and they
must be securely mounted to maintain the inherent stability of the original design. Genuine Yamaha Parts
and Accessories are designed and
tested to be compatible with your
motorcycle. Please consider Genuine Yamaha Parts and Accessories
before making a purchase. Use of
non-Yamaha-approved accessories
or replacement parts may cause
loss of handling stability and riding
safety. Since Yamaha cannot control the quality of accessories or
parts manufactured by other companies, Yamaha cannot be held lia@
E_5GK.book Page 26 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
ble for any consequences caused
by the use of items which have not
been approved by Yamaha.
@
EAU00695
Clutch lever free play
Since this model is equipped with a hydraulic 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
acceleration, there may be air in the
clutch system. If there is air in the hydraulic system, have a Yamaha dealer
bleed the system before operating the
motorcycle.
6-26
6
E_5GK.book Page 27 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
3. Tighten the locknut.
EW000099
@
WARNING
After adjusting the brake lever
free play, check the free play
and make sure that the brake is
working properly.
● 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 hydraulic system, have a Yamaha
dealer bleed the system before
operating the motorcycle. Air in
the hydraulic system will diminish the braking performance,
which may result in loss of control and an accident.
●
1. Locknut
2. Brake lever free play adjusting bolt
c. Brake lever free play
EAU00696
6
Adjusting the brake lever free
play
The brake lever free play should measure 2–5 mm (0.08–0.20 in) as shown.
Periodically check the brake lever free
play and, if necessary, adjust it as follows.
1. Loosen the locknut at the brake lever.
2. To increase the brake lever free
play, turn the adjusting bolt in direction a. To decrease the brake
lever free play, turn the adjusting
bolt in direction b.
@
6-27
a. Distance between brake pedal and footrest
EAU00712
Adjusting the brake pedal
position
The top of the brake pedal should be positioned approximately 20 mm (0.8 in)
below the top of the footrest as shown.
Periodically check the brake pedal position and, if necessary, have a Yamaha
dealer adjust it.
E_5GK.book Page 28 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000109
WARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of
air in the hydraulic system. If there
is air in the hydraulic system, have a
Yamaha dealer bleed the system before operating the motorcycle. Air in
the hydraulic system will diminish
the braking performance, which
may result in loss of control and an
accident.
@
@
1. Rear brake light switch
2. Rear brake light switch adjusting nut
1. Brake pad wear indicator
EAU00715
EAU00713
Adjusting the rear brake light
switch
The rear brake light switch, which is activated by the brake pedal, is properly
adjusted when the brake light comes
on just before braking takes effect. If
necessary, adjust the brake light switch
as follows.
Turn the adjusting nut while holding the
rear brake light switch in 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.
6-28
Checking the front and rear
brake pads
The front and rear brake pads must be
checked for wear at the intervals specified 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 indicator almost touches the brake disc,
have a Yamaha dealer replace the
brake pads as a set.
6
E_5GK.book Page 29 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Front brake
Clutch
1. Minimum level mark
1. Minimum level mark
EAU04169
Checking the brake and clutch
fluid levels
6
Rear brake
Insufficient brake fluid may allow air to
enter the brake or clutch systems, possibly causing them to become ineffective.
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 level is low, be sure to check the
brake pads for wear and the brake system for leakage.
NOTE:
The rear brake fluid reservoir is located
behind panel B. (See page 6-9 for panel
removal and installation procedures.)
_
_
Observe these precautions:
● 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
fluid: DOT 4 brake fluid
6-29
1. Panel B
2. Minimum level mark
●
Refill with the same type of brake
fluid. Mixing fluids may result in a
harmful chemical reaction and
lead to poor braking or clutch performance.
● 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.
● Be careful that water does not enter
the brake or clutch fluid reservoir
when refilling. Water will significantly
lower the boiling point of the fluid
and may result in vapor lock.
E_5GK.book Page 30 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
●
Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid
immediately.
● As the brake pads wear, it is normal for the brake fluid level to
gradually go down. However, if the
brake fluid level goes down suddenly, have a Yamaha dealer
check the cause.
EAU03984
EAU03297
Changing the brake and
clutch fluids
Checking and lubricating the
cables
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 calipers as well as the brake and clutch
hoses replaced at the intervals listed
below or whenever they are damaged
or leaking.
● Oil seals: Replace every two
years.
● Brake and clutch hoses: Replace
every four years.
The operation of all control cables and
the condition of the cables should be
checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged
or does not move smoothly, have a
Yamaha dealer check or replace it.
Recommended lubricant:
Yamaha Chain and Cable Lube
or engine oil SAE 10W-30
(API SE)
EW000111
WARNING
Damage to the outer housing of cables may result in internal rusting
and cause interference with cable
movement. Replace damaged cables as soon as possible to prevent
unsafe conditions.
@
@
6-30
6
E_5GK.book Page 31 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04034
Checking and lubricating the
throttle grip and cable
The operation of the throttle grip should
be checked before each ride. In addition, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.
EAU03370
Checking and lubricating the
brake and shift pedals
6
The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
6-31
E_5GK.book Page 32 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EAU03164
EAU03371
Checking and lubricating the
brake and clutch levers
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 lubricated if necessary.
The operation of the centerstand and
sidestand should be checked before
each ride, and the pivots and metal-tometal contact surfaces should be lubricated if necessary.
Recommended lubricant:
Lithium-soap-based grease
(all-purpose grease)
EW000114
WARNING
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or repair it.
@
@
6-32
6
E_5GK.book Page 33 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU02939
Checking the front fork
The condition and operation of the front
fork must be checked as follows at the
intervals specified in the periodic maintenance and lubrication chart.
To check the condition
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
EAU04282
Lubricating the rear
suspension
6
The pivoting points of the rear suspension must be lubricated at the intervals
specified in the periodic maintenance
and lubrication chart.
@
Check the inner tubes for scratches,
damage and excessive oil leakage.
Recommended lubricant:
Lithium-soap-based grease
To check the operation
1. Place the motorcycle on a level
surface and hold it in an upright
position.
2. While applying the front brake,
push down hard on the handlebars several times to check if the
front fork compresses and rebounds smoothly.
EC000098
CAUTION:
If any damage is found or the front
fork does not operate smoothly,
have a Yamaha dealer check or repair it.
@
@
6-33
E_5GK.book Page 34 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU00794
Checking the steering
Worn or loose steering bearings may
cause danger. Therefore, the operation
of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication
chart.
1. Place a stand under the engine to
raise the front wheel off the
ground.
EW000115
WARNING
Securely support the motorcycle so
that there is no danger of it falling
over.
@
2. Hold the lower ends of the front
fork legs and try to move them forward and backward. If any free
play can be felt, have a Yamaha
dealer check or repair the steering.
@
6-34
6
E_5GK.book Page 35 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU01144
Checking the wheel bearings
The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrication chart. If there is play in the wheel
hub or if the wheel does not turn
smoothly, have a Yamaha dealer
check the wheel bearings.
1. Battery
2. Battery breather hose
3. Pass through the cable guide.
1. Maximum level mark
2. Minimum level mark
EAU04864
Battery
6
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 intervals specified in the periodic maintenance and lubrication chart.
To check the electrolyte level
1. Place the motorcycle on the centerstand.
NOTE:
Make sure that the motorcycle is positioned straight up when checking the
electrolyte level.
_
_
2. Check the electrolyte level in the
battery.
NOTE:
The electrolyte should be between the
minimum and maximum level marks.
_
_
6-35
E_5GK.book Page 36 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
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 for rider seat removal
and installation procedures.)
1. Starter moter lead (black)
2. Positive battery lead (red)
3. Negative battery lead
5. Disconnect the negative battery
lead from the battery.
6. Disconnect the positive battery
lead and the starter motor lead
from the starter motor relay.
6-36
1. Ignition coil assembly (× 2)
2. Bolt (× 2)
3. Coupler (× 4)
7. Disconnect the couplers shown.
8. Remove the ignition coil assemblies by removing the bolts.
9. Add distilled water to raise the
electrolyte to the maximum level
mark.
6
E_5GK.book Page 37 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
●
EW000116
_
6
WARNING
● Electrolyte is poisonous and
dangerous since it contains sulfuric acid, which causes severe
burns. Avoid any contact with
skin, eyes or clothing and always shield your eyes when
working near batteries. In case
of contact, administer the following FIRST AID.
• EXTERNAL: Flush with plenty
of water.
• INTERNAL: Drink large quantities of water or milk and immediately call a physician.
• EYES: Flush with water for 15
minutes and seek prompt
medical attention.
● Batteries produce explosive hydrogen gas. Therefore, keep
sparks, flames, cigarettes, etc.,
away from the battery and provide sufficient ventilation when
charging it in an enclosed
space.
KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF
CHILDREN.
_
EC000100
CAUTION:
Use only distilled water, as tap water
contains minerals that are harmful
to the battery.
_
_
1. Battery
2. Battery breather hose
3. Pass through the cable guide.
10. Check and, if necessary, correct
the breather hose routing.
11. Install the ignition coil assemblies
by installing the bolts.
12. Connect the couplers.
6-37
E_5GK.book Page 38 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Positive battery lead (red)
2. Starter motor lead (black)
13. Connect and tighten the positive
battery lead and the starter motor
lead to the starter motor relay.
EW000118
WARNING
Pass the positive battery lead and
starter lead through the hole in the
ignition coil bracket as shown. Improper routing of these leads could
bring about a short circuit, causing
the engine and lights to fail and possibly resulting in an accident.
_
To store the battery
1. If the motorcycle will not be used
for more than one month, remove
the battery, fully charge it, and
then place it in a cool, dry place.
2. If the battery will be stored for
more than two months, check the
specific gravity of the electrolyte at
least once a month and fully
charge the battery whenever necessary.
3. Fully charge the battery before installation.
4. After installation, make sure that
the battery leads are properly connected to the battery terminals and
that the breather hose is properly
routed, in good condition, and not
obstructed.
_
14. Connect and tighten the negative
battery lead to the battery.
15. Install the rider seat.
6-38
EC000099
CAUTION:
If the breather hose is positioned in
such a way that the frame is exposed to electrolyte or gas expelled
from the battery, the frame could
suffer structural and external damages.
_
_
6
E_5GK.book Page 39 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EC000103
CAUTION:
Do not use a fuse of a higher amperage rating than recommended to
avoid causing extensive damage to
the electrical system and possibly a
fire.
@
@
1. Main fuse
2. Spare main fuse
EAU01664
Replacing the fuses
6
The main fuse box is located under the
rider seat. (See page 3-9 for rider seat
removal and installation procedures.)
The fuse box, which contains the fuses
for the individual circuits, is located under cowling A. (See page 6-8 for cowling removal and installation procedures.)
If a fuse is blown, replace it as follows.
1. Turn the key to “OFF” and turn off
the electrical circuit in question.
2. Remove the blown fuse, and then
install a new fuse of the specified
amperage.
1.
2.
3.
4.
5.
3. Turn the key to “ON” and turn on
the electrical circuit in question to
check if the device operates.
4. If the fuse immediately blows
again, have a Yamaha dealer
check the electrical system.
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Spare fuse (× 2)
Specified fuses:
Main fuse:
Headlight fuse:
Signaling system fuse:
Radiator fan fuse:
Ignition fuse:
6-39
30 A
15 A
10 A
10 A
10 A
E_5GK.book Page 40 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (× 2)
1. Headlight bulb holder
3. Remove the headlight bulb holder
by turning it counterclockwise, and
then remove the defective bulb.
EAU04187
Replacing the headlight bulb
This motorcycle is equipped with a
quartz bulb headlight. If the headlight
bulb burns out, replace it as follows.
1. Remove the headlight unit by removing the screws.
2. Disconnect the headlight coupler,
and then remove the bulb cover.
1. Do not touch the glass part of the bulb.
EW000119
WARNING
Headlight bulbs get very hot. Therefore, keep flammable products away
from a lit headlight bulb, and do not
touch the bulb until it has cooled
down.
_
_
4. Place a new headlight bulb into
position, and then secure it with
the bulb holder.
6-40
EC000105
CAUTION:
Do not touch the glass part of the
headlight bulb to keep it free from
oil, otherwise the transparency of
the glass, the luminosity of the bulb,
and the bulb life will be adversely affected. Thoroughly clean off any dirt
and fingerprints on the headlight
bulb using a cloth moistened with
alcohol or thinner.
_
_
5. Install the headlight bulb cover,
and then connect the coupler.
6. Install the headlight unit by installing the screws.
7. Have a Yamaha dealer adjust the
headlight beam if necessary.
6
E_5GK.book Page 41 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Screw (× 2)
1. Tail/brake light bulb (× 2)
EAU00855
Replacing a turn signal light
bulb or the tail/brake light
bulb
6
1. Remove the lens by removing the
screws.
2. Remove the defective bulb by
pushing it in and turning it counterclockwise.
3. Insert a new bulb into the socket,
push it in, and then turn it clockwise until it stops.
1. Turn signal light bulb
4. Install the lens by installing the
screws.
EC000108
CAUTION:
Do not overtighten the screws, otherwise the lens may break.
@
@
6-41
E_5GK.book Page 42 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU04163
Front wheel
To remove the front wheel
EW000122
_
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
_
1. Place the motorcycle on the centerstand.
1.
2.
3.
4.
Speedometer cable
Bolt (× 2)
Front wheel axle pinch bolt
Wheel axle
EAU04360
2. Disconnect the speedometer cable from the front wheel.
3. Remove the brake calipers by removing the bolts.
ECA00047
CAUTION:
Do not pull the brake lever after the
brake caliper has been removed,
otherwise the brake pads will be
forced shut.
_
_
4. Loosen the front wheel axle pinch
bolt, then the wheel axle.
5. Pull the wheel axle out, and then
remove the wheel.
6-42
To install the front wheel
1. Install the speedometer gear unit
into the wheel hub so that the projections mesh with the slots.
6
E_5GK.book Page 43 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake calipers onto the brake
discs.
_
_
1. Retainer
2. Lift the wheel up between the fork
legs.
NOTE:
Make sure that the slot in the speedometer gear unit fits over the retainer on
the fork leg.
_
6
_
3. Insert the wheel axle.
4. Install the brake calipers by installing the bolts.
5. Install the brake hose holders by
installing the bolts.
6. Take the motorcycle off the centerstand so that the front wheel is
on the ground.
7. Tighten the wheel axle, then the
front wheel axle pinch bolt and the
brake caliper bolts to the specified
torques.
Tightening torques:
Wheel axle:
58 Nm (5.8 m·kgf, 42 ft·lbf)
Front wheel axle pinch bolt:
20 Nm (2.0 m·kgf, 14 ft·lbf)
Brake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf)
8. Connect the speedometer cable.
6-43
9. Push down hard on the handlebar
several times to check for proper
fork operation.
E_5GK.book Page 44 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
1. Axle nut
1. Rear wheel axle pinch bolt
EAU04361
Rear wheel
To remove the rear wheel
EW000122
_
WARNING
● It is advisable to have a Yamaha
dealer service the wheel.
● Securely support the motorcycle so that there is no danger
of it falling over.
1. Remove the axle nut, and then
loosen the rear wheel axle pinch
bolt.
2. Place the motorcycle on the centerstand.
_
6-44
1.
2.
3.
4.
5.
6.
Nut
Cotter pin
Brake torque rod
Bolt (× 3)
Spacer
Brake caliper bracket
3. Remove the brake caliper by removing the bolts.
4. Disconnect the brake torque rod
from the brake caliper bracket by
removing the cotter pin, the nut,
and the bolt.
6
E_5GK.book Page 45 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
5. While supporting the rear wheel,
pull the wheel axle out.
6. Remove the brake caliper bracket
and spacer.
7. Pull the wheel to the right to separate it from the final gear case, and
then remove it.
6
ECA00062
CAUTION:
Do not push the brake pedal after
the wheel has been removed together with the brake disc, otherwise the
brake pads will be forced shut.
_
_
EAU04362
To install the rear wheel
1. Apply a light coating of lithiumsoap-based grease to the splines
of the final gear case and wheel
hub.
2. Install the wheel, brake caliper
bracket, spacer and wheel axle.
3. Install the brake caliper by installing the bolts.
NOTE:
Make sure that there is enough space
between the brake pads before installing the brake caliper onto the brake
disc.
_
_
6-45
4. Connect the brake torque rod to
the brake caliper bracket by installing the bolt and the nut.
5. Install the axle nut, and then slightly tighten it.
6. Take the motorcycle off the centerstand 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·lbf)
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)
8. Install the brake torque rod cotter
pin.
E_5GK.book Page 46 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EW000124
WARNING
Always use a new cotter pin.
_
_
EAU03087
Troubleshooting
Although Yamaha motorcycles receive
a thorough inspection before shipment
from the factory, trouble may occur during 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 yourself. However, should your motorcycle
require any repair, take it to a Yamaha
dealer, whose skilled technicians have
the necessary tools, experience, and
know-how to service the motorcycle
properly.
Use only genuine Yamaha replacement parts. Imitation parts may look
like Yamaha parts, but they are often
inferior, have a shorter service life and
can lead to expensive repair bills.
6-46
6
E_5GK.book Page 47 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
EAU03363
Troubleshooting charts
Starting problems or poor engine performance
EW000125
WARNING
Keep away open flames and do not smoke while checking or working on the fuel system.
@
@
1. Fuel
There is enough fuel.
Check the compression.
There is no fuel.
Supply fuel.
Check the fuel level in
the fuel tank.
The engine does not start.
Check the compressoin.
2. Compression
6
There is compression.
Check the ignition.
There is no compression.
Have a Yamaha dealer
check the vehicle.
Operate the electric starter.
3. Ignition
Wet
Wipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Open the throttle halfway and operate
the electric starter.
Dry
Have a Yamaha dealer check the vehicle.
The engine does not start.
Check the battery.
Remove the spark plugs
and check the electrodes.
4. Battery
The engine turns over
quickly.
The battery is good.
Operate the electric starter.
The engine turns over
slowly.
Check the electrolyte and battery
lead connections, and charge the
battery if necessary.
6-47
The engine does not start.
Have a Yamaha dealer
check the vehicle.
E_5GK.book Page 48 Friday, May 31, 2002 10:59 AM
PERIODIC MAINTENANCE AND MINOR REPAIR
Engine overheating
EW000070
@
WARNING
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.
● 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.
●
@
The coolant level is low.
Check the cooling system
for leakage.
Wait until the
engine has cooled.
Check the coolant level in the
reservoir and radiator.
The coolant level
is OK.
There is
leakage.
There is
no leakage.
Have a Yamaha dealer check
and repair the cooling system.
Add coolant. (See NOTE.)
Start the engine. If the engine overheats again, have a
Yamaha dealer check and repair the cooling system.
NOTE:
If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant
as soon as possible.
@
@
6-48
6
E_5GK.book Page 49 Friday, May 31, 2002 10:59 AM
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
MOTORCYCLE CARE AND STORAGE
Care .................................................................................................. 7-1
Storage .............................................................................................. 7-4
7
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
MOTORCYCLE CARE AND STORAGE
EAU03412
7-
Care
While the open design of a motorcycle
reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop
even if high-quality components are
used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts
from the overall appearance of a
motorcycle. Frequent and proper care
does not only comply with the terms of
the warranty, but it will also keep your
motorcycle looking good, extend its life
and optimize its performance.
Before cleaning
1. Cover the muffler outlets with plastic 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 installed.
3. Remove extremely stubborn dirt,
like oil burnt onto the crankcase,
with a degreasing agent and a
brush, but never apply such products onto seals, gaskets and
wheel axles. Always rinse the dirt
and degreaser off with water.
7
7-1
Cleaning
ECA00010
@
CAUTION:
● 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 affected area any longer than instructed. Also, thoroughly rinse
the area off with water, immediately dry it, and then apply a
corrosion 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_5GK.book Page 2 Friday, May 31, 2002 10:59 AM
MOTORCYCLE CARE AND STORAGE
●
Do not use any harsh chemical
products on plastic parts. Be
sure to avoid using cloths or
sponges which have been in
contact with strong or abrasive
cleaning products, solvent or
thinner, fuel (gasoline), rust removers or inhibitors, brake fluid, antifreeze or electrolyte.
● Do not use high-pressure washers or steam-jet cleaners since
they cause water seepage and
deterioration in the following areas: seals (of wheel and swingarm 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
compounds for plastic may
leave scratches on the windshield. Test the product on a
small hidden 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 riding in the rain, near the sea or
on salt-sprayed roads
Since sea salt or salt sprayed on roads
during winter are extremely corrosive in
combination with water, carry out the
following steps after each ride in the
rain, near the sea or on salt-sprayed
roads.
NOTE:
Salt sprayed on roads in the winter may
remain well into spring.
@
@
1. Clean the motorcycle with cold
water and a mild detergent, after
the engine has cooled down.
@
ECA00012
After normal use
Remove dirt with warm water, a mild
detergent, and a soft, clean sponge,
and then rinse thoroughly with clean
water. Use a toothbrush or bottlebrush
for hard-to-reach areas. Stubborn dirt
and insects will come off more easily if
the area is covered with a wet cloth for
a few minutes before cleaning.
7-2
CAUTION:
Do not use warm water since it increases the corrosive action of the
salt.
@
@
2. After drying the motorcycle, apply
a corrosion protection spray on all
metal, including chrome- and nickel-plated, surfaces to prevent corrosion.
7
E_5GK.book Page 3 Friday, May 31, 2002 10:59 AM
MOTORCYCLE CARE AND STORAGE
7
After cleaning
1. Dry the motorcycle with a chamois
or an absorbing cloth.
2. Use a chrome polish to shine
chrome, aluminum and stainlesssteel parts, including the exhaust
system. (Even the thermally induced discoloring of stainlesssteel exhaust systems can be removed through polishing.)
3. To prevent corrosion, it is recommended to apply a corrosion protection spray on all metal,
including chrome- and nickel-plated, surfaces.
4. Use spray oil as a universal cleaner to remove any remaining dirt.
5. Touch up minor paint damage
caused by stones, etc.
6. Wax all painted surfaces.
7. Let the motorcycle dry completely
before storing or covering it.
@
EWA00031
ECA00013
WARNING
● Make sure that there is no oil or
wax on the brakes or tires.
● If necessary, clean the brake
discs and brake linings with a
regular brake disc cleaner or acetone, and wash the tires with
warm water and a mild detergent. Before riding at higher
speeds, test the motorcycle’s
braking performance and cornering behavior.
CAUTION:
● Apply spray oil and wax sparingly and make sure to wipe off
any excess.
● Never apply oil or wax to any
rubber and plastic parts, but
treat them with a suitable care
product.
● Avoid using abrasive polishing
compounds as they will wear
away the paint.
@
@
NOTE:
Consult a Yamaha dealer for advice on
what products to use.
@
@
@
7-3
E_5GK.book Page 4 Friday, May 31, 2002 10:59 AM
MOTORCYCLE CARE AND STORAGE
Storage
Short-term
Always store your motorcycle in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00014
@
@
CAUTION:
● Storing the motorcycle in a
poorly ventilated room or covering it with a tarp, while it is still
wet, will allow water and humidity to seep in and cause rust.
● To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemicals are stored.
Long-term
Before storing your motorcycle for
several months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. For motorcycles equipped with a
fuel cock that has an “OFF” position: Turn the fuel cock lever to
“OFF”.
3. Drain the carburetor float chambers by loosening the drain bolts;
this will prevent fuel deposits from
building up. Pour the drained fuel
into the fuel tank.
4. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
5. Perform the following steps to protect 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 sparking 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.
EWA00003
WARNING
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turning
the engine over.
@
@
7-4
7
E_5GK.book Page 5 Friday, May 31, 2002 10:59 AM
MOTORCYCLE CARE AND STORAGE
7
6. Lubricate all control cables and
the pivoting points of all levers and
pedals as well as of the sidestand/
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. Alternatively, 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 plastic 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 excessively cold or warm place [less
than 0 °C (30 °F) or more than
30 °C (90 °F)]. For more information on storing the battery, see
page 6-38.
NOTE:
Make any necessary repairs before
storing the motorcycle.
@
@
7-5
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
SPECIFICATIONS
Specifications .................................................................................... 8-1
8
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
SPECIFICATIONS
EAU01038
8-
Specifications
CS-01E
Model
Engine oil
VMX12/VMX12C
Type
Dimensions
Overall length
Overall width
Overall height
795 mm (31.3 in)
765 mm (30.1 in)
Wheelbase
1,590 mm (62.6 in)
Minimum turning radius
145 mm (5.7 in)
-20 -10
Recommended engine oil
classification
Basic weight (with oil and full
fuel tank)
283 kg (624 lb)
VMX12C
284 kg (626 lb)
8
V type, 4-cylinder
Displacement
1,198 cm3
Bore × stroke
76 × 66 mm (3.0 × 2.6 in)
Compression ratio
10.5:1
Starting system
Electric starter
Lubrication system
70
90
110 130 ˚F
0
10
20
30
40
50 ˚C
API Service SE, SF, SG or
higher
CAUTION:
Liquid-cooled 4-stroke, DOHC
Cylinder arrangement
50
In order to prevent clutch slippage (since the engine oil also
lubricates the clutch), do not mix any chemical additives. Do
not use oils with a diesel specification of “CD” or oils of a
higher quality than specified. In addition, do not use oils labeled “ENERGY CONSERVING II” or higher.
Engine
Engine type
30
YAMALUBE 4 (20W-40)
or SAE 20W-40
2,900 mm (114.2 in)
VMX12
10
YAMALUBE 4 (10W-30)
or SAE 10W-30
1,160 mm (45.7 in)
Seat height
Ground clearance
0
2,300 mm (90.6 in)
Quantity
Wet sump
8-1
Without oil filter cartridge
replacement
3.2 L (2.82 Imp qt, 3.38 US qt)
With oil filter cartridge
replacement
3.4 L (2.99 Imp qt, 3.59 US qt)
Total amount (dry engine)
4 L (3.52 Imp qt, 4.23 US qt)
E_5GK.book Page 2 Friday, May 31, 2002 10:59 AM
SPECIFICATIONS
Final gear oil
Type
Quantity
Cooling system capacity
(total amount)
Air filter
Operation
Hypoid gear oil SAE80 (API
GL4) or multi-grade hypoid gear
oil SAE80W-90
Left foot
Gear ratio
1st
2.529
2nd
1.772
3rd
1.347
3.05 L (2.68 Imp qt, 3.22 US qt)
4th
1.076
Dry element
5th
0.928
0.2 L (0.18 Imp qt, 0.21 US qt)
Chassis
Fuel
Frame type
Double cradle
Type
UNLEADED GASOLINE ONLY
Fuel tank capacity
15 L (3.3 Imp gal, 4.0 US gal)
Caster angle
29°
3 L (0.7 Imp gal, 0.8 US gal)
Trail
119 mm (4.69 in)
Fuel reserve amount
Tires
Carburetor
Manufacturer
MIKUNI
Model × quantity
BDS35 × 4
Front
Spark plug
Manufacturer/model
Gap
Clutch type
Type
Tubeless tire
Size
110/90-18 M/C 61V
110/90-18 61V
DPR8EA-9 / NGK or
X24EPR-U9 / DENSO
Manufacturer/
model
0.8–0.9 mm (0.03–0.04 in)
Wet, multiple-disc
Bridgestone / G525AW
Dunlop / F20
Rear
Transmission
Primary reduction system
Spur gear
Primary reduction ratio
1.775
Secondary reduction system
Shaft drive
Secondary reduction ratio
2.851
Transmission type
Constant mesh, 5-speed
Type
Tubeless tire
Size
150/90-15 M/C 74V
Manufacturer/
model
8-2
Bridgestone / G526BW
Dunlop / K525
8
E_5GK.book Page 3 Friday, May 31, 2002 10:59 AM
SPECIFICATIONS
Maximum load*
VMX12
216 kg (476 lb)
VMX12C
215 kg (474 lb)
Up to 90 kg (198 lb)*
225 kPa (2.25 kgf/cm2, 33 psi)
Rear
225 kPa (2.25 kgf/cm2, 33 psi)
225 kPa (2.25 kgf/cm2, 33 psi)
Rear
250 kPa (2.50 kgf/cm2, 36 psi)
225 kPa (2.25 kgf/cm2, 33 psi)
Rear
250 kPa (2.50 kgf/cm2, 36 psi)
Type
Single disc brake
Operation
Right foot
Fluid
DOT 4
Front
Telescopic fork
Rear
Swingarm
Front
Coil-air spring / oil damper
Rear
Coil spring / oil damper
Wheel travel
* Total weight of rider, passenger, cargo and accessories
Wheels
Front
140 mm (5.5 in)
Rear
100 mm (3.9 in)
Electrical system
Front
8
DOT 4
Spring/shock absorber
High-speed riding
Front
Fluid
Suspension
90 kg (198 lb)–maximum*
Front
Right hand
Rear
Tire air pressure (measured
on cold tires)
Front
Operation
Type
Cast wheel
Size
18 × MT 2.15
Type
Cast wheel
Ignition system
Charging system
Rear
Size
Type
A.C. magneto
Standard output
14 V, 22.5 A@ 5,000 r/min
Battery
15M/C × MT 3.50
Brakes
Front
Type
T.C.I. (digital)
Model
YB16AL-A2
Voltage, capacity
12 V, 16 Ah
Headlight type
Dual disc brake
8-3
Quartz bulb (halogen)
E_5GK.book Page 4 Friday, May 31, 2002 10:59 AM
SPECIFICATIONS
Bulb voltage, wattage × quantity
Headlight
12 V, 60/55 W × 1
Tail/brake light
12 V, 8/27 W × 2
Front turn signal/position light
12 V, 27/8 W × 2
Rear turn signal light
12 V, 27 W × 2
Meter lighting
14 V, 3 W × 2
Neutral indicator light
14 V, 3 W × 1
High beam indicator light
14 V, 3 W × 1
Turn signal indicator light
14 V, 3 W × 1
Fuel level warning light
14 V, 3 W × 1
Oil level warning light
14 V, 3 W × 1
Fuses
Main fuse
30 A
Headlight fuse
15 A
Signaling system fuse
10 A
Radiator fan fuse
10 A
Ignition fuse
10 A
8
8-4
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
Identification numbers ....................................................................... 9-1
Key identification number .................................................................. 9-1
Vehicle identification number ............................................................. 9-1
Model label ........................................................................................ 9-2
Reporting safety defects ................................................................... 9-3
Motorcycle noise regulation .............................................................. 9-4
Maintenance record .......................................................................... 9-5
YAMAHA MOTOR CORPORATION, U.S.A. STREET AND
ENDURO MOTORCYCLE LIMITED WARRANTY .......................... 9-7
YAMAHA EXTENDED SERVICE (Y.E.S.) ......................................... 9-9
9
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
EAU01039
9-
EAU02944
Identification numbers
Record the key identification number,
vehicle identification number and model label information in the spaces provided below for assistance when
ordering spare parts from a Yamaha
dealer or for reference in case the vehicle is stolen.
1. KEY IDENTIFICATION NUMBER:
1. Key identification number
CA-02E
2. VEHICLE IDENTIFICATION
NUMBER:
1. Vehicle identification number
EAU01042
EAU01043
Key identification number
Vehicle identification number
The key identification number is
stamped into the key. Record this number in the space provided and use it for
reference when ordering a new key.
The vehicle identification number is
stamped into the steering head pipe.
Record this number in the space provided.
CA-02E
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcycle with the licensing authority in
your area.
@
9
3. MODEL LABEL INFORMATION:
CA-01E
@
9-1
E_5GK.book Page 2 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
1. Model label
EAU03424
Model label
The model label is affixed under cowling A. (See page 6-8 for cowling removal and installation procedures.)
Record the information on this label in
the space provided. This information
will be needed when ordering spare
parts from a Yamaha dealer.
9
9-2
E_5GK.book Page 3 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
EAU01051
Reporting safety defects
If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should 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 group
of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems
between you, your dealer, or Yamaha Motor Corporation, U.S.A.
To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other information about motor vehicle safety from the Hotline.
9
9-3
E_5GK.book Page 4 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
EAU01053
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 vehicle 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.
CL-01E
Exhaust system
Muffler
Exhaust pipe
Silencer
Intake system
Air cleaner case
Air cleaner element
Intake duct
9
9-4
E_5GK.book Page 5 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
EAU01874
Maintenance record
Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that
maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder
that maintenance work is required. It is not acceptable proof of maintenance work.
CL-04E
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
600 mi
(1,000 km) or
1 month
4,000 mi
(7,000 km) or
6 months
8,000 mi
(13,000 km) or
12 months
12,000 mi
(19,000 km) or
18 months
16,000 mi
(25,000 km) or
24 months
9
20,000 mi
(31,000 km) or
30 months
24,000 mi
(37,000 km) or
36 months
9-5
Remarks
E_5GK.book Page 6 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
Maintenance
interval
Date of
service
Servicing dealer
name and address
Mileage
Remarks
28,000 mi
(43,000 km) or
42 months
32,000 mi
(49,000 km) or
48 months
36,000 mi
(55,000 km) or
54 months
40,000 mi
(61,000 km) or
60 months
9
9-6
E_5GK.book Page 7 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
EAU02918
YAMAHA MOTOR CORPORATION, U.S.A.
STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY
9
9-7
E_5GK.book Page 8 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
9
9-8
E_5GK.book Page 9 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
EAU01063
YAMAHA EXTENDED SERVICE (Y.E.S.)
9
9-9
E_5GK.book Page 10 Friday, May 31, 2002 10:59 AM
CONSUMER INFORMATION
9
9-10
E_5GK.book Page 1 Friday, May 31, 2002 10:59 AM
INDEX
10-
A
D
M
Accessories and replacement parts .......6-25
Air filter element, cleaning ......................6-21
Dimmer switch......................................... 3-3
Main switch ..............................................3-1
Maintenance and lubrication, periodic ......6-5
Maintenance, emission control system.....6-3
Maintenance, periodic ..............................6-1
Maintenance record .................................9-5
Model label ..............................................9-2
B
Battery ...................................................6-35
Brake and clutch fluid levels, checking ...6-29
Brake and clutch fluids, changing...........6-30
Brake and clutch levers, checking and
lubricating ............................................6-32
Brake and shift pedals, checking and
lubricating ............................................6-31
Brake lever...............................................3-5
Brake lever free play, adjusting ..............6-27
Brake light switch (rear), adjusting .........6-28
Brake pads, checking.............................6-28
Brake pedal..............................................3-6
Brake pedal position, adjusting ..............6-27
C
Cables, checking and lubricating............6-30
Canister (for California only)...................6-11
Carburetors, adjusting............................6-22
Care.........................................................7-1
Centerstand and sidestand, checking
and lubricating .....................................6-32
Clutch lever..............................................3-5
Clutch lever free play .............................6-26
Coolant ..................................................6-16
Changing..........................................6-17
Checking ..........................................6-16
Coolant temperature gauge .....................3-3
Cowling and panels,
removing and installing ..........................6-8
E
Engine break-in ....................................... 5-5
Engine oil and oil filter cartridge ............. 6-11
Engine stop switch................................... 3-4
F
Final gear oil.......................................... 6-15
Front fork, adjusting............................... 3-11
Front fork, checking ............................... 6-33
Fuel ......................................................... 3-7
Fuel level warning light ............................ 3-2
Fuel reserve switch.................................. 3-4
Fuel tank cap........................................... 3-6
Fuses, replacing .................................... 6-39
H
Handlebar switches ................................. 3-3
Headlight bulb, replacing ....................... 6-40
Helmet holder ........................................ 3-10
High beam indicator light ......................... 3-2
Horn switch ............................................. 3-4
I
Identification numbers ............................. 9-1
Ignition circuit cut-off system.................. 3-17
Indicator and warning lights ..................... 3-1
K
Key identification number ........................ 9-1
L
Labels, location ....................................... 1-7
N
Neutral indicator light ...............................3-1
Noise regulation .......................................9-4
O
Oil level warning light ...............................3-2
P
Parking.....................................................5-6
Part locations ...........................................2-1
Pre-operation check list............................4-1
R
Rear suspension, lubricating ..................6-33
Rider seat ................................................3-9
S
Safety defects, reporting ..........................9-3
Safety information ....................................1-1
Shifting.....................................................5-3
Decelerating .......................................5-4
Shift points..........................................5-5
Starting out and accelerating ..............5-4
Shift pedal................................................3-5
Shock absorber assemblies, adjusting ...3-12
Sidestand...............................................3-17
Spark plugs, checking ..............................6-9
E_5GK.book Page 2 Friday, May 31, 2002 10:59 AM
INDEX
Specifications .......................................... 8-1
Speedometer unit .................................... 3-2
Starter (choke) lever ................................ 3-8
Starting and warming up a cold engine.... 5-1
Starting a warm engine............................ 5-3
Start switch.............................................. 3-4
Steering, checking ................................. 6-34
Steering lock............................................ 3-9
Storage.................................................... 7-4
Suspension settings, matching
front and rear....................................... 3-15
T
Tachometer ............................................. 3-3
Throttle cable free play, adjusting .......... 6-22
Throttle grip and cable, checking and
lubricating............................................ 6-31
Tires ...................................................... 6-23
Tool kit..................................................... 6-1
Troubleshooting..................................... 6-46
Troubleshooting charts .......................... 6-47
Turn signal indicator light ......................... 3-1
Turn signal light bulb or
the tail/brake light bulb, replacing ........ 6-41
Turn signal switch.................................... 3-3
V
Valve clearance, adjusting..................... 6-22
V-Boost ................................................. 3-16
Vehicle identification number ................... 9-1
W
Warranty, extended ................................. 9-9
Warranty, limited...................................... 9-7
Wheel bearings, checking ..................... 6-35
Wheel (front) ......................................... 6-42
Installing .......................................... 6-42
Removing ........................................ 6-42
Wheel (rear) .......................................... 6-44
Installing .......................................... 6-45
Removing ........................................ 6-44
Wheels.................................................. 6-25
OWNER’S MANUAL
VMX12R
VMX12RC
YAMAHA MOTOR CO., LTD.
PRINTED ON RECYCLED PAPER
PRINTED IN JAPAN
2002.05-0.9×1 CR
(E)
LIT-11626-16-20
5GK-28199-13