OWNER’S MANUAL VMX12V(C) LIT-11626-19-27 5GK-28199-16
EAU10041
INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha VMX12V. 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.
IMPORTANT MANUAL INFORMATION EAU10130 Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the WARNING motorcycle operator, a bystander or a person inspecting or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to CAUTION: the motorcycle.
IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE VMX12V(C) OWNER’S MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2005 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.
TABLE OF CONTENTS SAFETY INFORMATION ...................1-1 Location of important labels .............1-5 DESCRIPTION ...................................2-1 Left view ...........................................2-1 Right view .........................................2-2 Controls and instruments..................2-3 INSTRUMENT AND CONTROL FUNCTIONS ........................................3-1 Main switch ......................................3-1 Indicator and warning lights .............3-1 Speedometer unit ..
TABLE OF CONTENTS Checking the wheel bearings ........6-30 Battery ...........................................6-31 Replacing the fuses .......................6-33 Replacing the headlight bulb .........6-34 Replacing a turn signal light bulb or the tail/brake light bulb ...............6-35 Front wheel ....................................6-36 Rear wheel ....................................6-37 Troubleshooting .............................6-39 Troubleshooting charts ..................
SAFETY INFORMATION EAU10272 TIONS. ● 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: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION. THE WARNINGS ● OBSERVE AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.
SAFETY INFORMATION ed by road and traffic conditions. Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control. The operator should keep both hands on the handlebar and both feet on the operator footrests during operation to maintain control of the motorcycle.
SAFETY INFORMATION Maximum load: 215 kg (474 lb) (CAL)(ZAF) 216 kg (476 lb) (U49) 1 When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability. ● Shifting weights can create a sudden imbalance.
SAFETY INFORMATION could cause a dangerous loss of lights or engine power. Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: Always turn the engine off when refueling. Take care not to spill any gasoline on the engine or exhaust system when refueling. Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
SAFETY INFORMATION 4 1 1 2 CALIFORNIA ONLY 5 00 3 1-6
DESCRIPTION EAU10410 Left view 1 2 3 4 5 6 7 8 9 1. Clutch fluid reservoir (page 6-25) 2. Air filter element (page 6-18) 3. Fuse box (page 6-33) 4. Main fuse box (page 6-33) 5. Owner’s tool kit (page 6-1) 6. Shock absorber assembly spring preload adjusting ring (page 3-12) 7. Shock absorber assembly damping force adjusting knob (page 3-12) 8. Helmet holder (page 3-10) 9. Shift pedal (page 3-5) 10.
DESCRIPTION EAU10420 Right view 2 3 4 5 6 7 1. Fuel tank cap (page 3-6) 2. Battery (page 6-31) 3. Coolant reservoir (page 6-15) 4. Front brake fluid reservoir (page 6-25) 5. Main switch (page 3-1) 6. Radiator cap (page 6-15) 7. Radiator (page 6-15) 8. Engine oil filter cartridge (page 6-11) 9. Engine oil level check window (page 6-11) 10. Brake pedal (page 3-6) 11.
DESCRIPTION EAU10430 Controls and instruments 1 2 3 4 5 6 7 8 9 1. Clutch lever (page 3-5) 2. Left handlebar switches (page 3-3) 3. Speedometer unit (page 3-2) 4. Right handlebar switches (page 3-3) 5. Brake lever (page 3-5) 6. Throttle grip (page 6-19) 7. Tachometer (page 3-3) 8.
INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch EAU10822 EAU11003 Indicator and warning lights P (Parking) 2 3 The main switch controls the ignition and lighting systems. The various main switch positions are described below. EAU10510 ON All electrical systems are supplied with power, and the headlight, meter lighting, taillight and position lights come on, and the engine can be started. The key cannot be removed. EAU10660 1. Push. 2. Turn.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 8 9 EAU11090 EAU32320 High beam indicator light “HIGH BEAM” This indicator light comes on when the high beam of the headlight is switched on. Fuel level warning light “FUEL” This warning light comes on when the fuel level drops below approximately 3.0 L (0.79 US gal) (0.66 Imp.gal). When this occurs, set the fuel reserve switch to the “RES” position and refuel as soon as possible.
INSTRUMENT AND CONTROL FUNCTIONS EAU11851 Tachometer EAU12171 Coolant temperature gauge EAU12343 Handlebar switches Left 2 3 1. Tachometer 2. Tachometer red zone 4 1. Coolant temperature gauge 2. Coolant temperature gauge red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. ECA10031 CAUTION: Do not operate the engine in the tachometer red zone.
INSTRUMENT AND CONTROL FUNCTIONS EAU12410 Dimmer switch “LIGHTS” Set the switch to “HI” for the high beam and to “LO” for the low beam. EAU12650 1 EAU12420 2 3 4 5 6 7 8 9 EAU12510 Horn switch “HORN” Press this switch to sound the horn. 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.
INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12870 Shift pedal EAU12890 Brake lever 2 3 1. Clutch 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 3-15.) 1.
INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13060 Fuel tank cap To remove the fuel tank cap 1 2 3 1. Unlock. 4 5 6 7 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. 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Opening lever 1.
INSTRUMENT AND CONTROL FUNCTIONS unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked. EAU13210 Fuel fuel may deteriorate painted surfaces or plastic parts. EAU13300 EWA10130 WARNING Make sure that the fuel tank cap is properly installed before riding. Recommended fuel: UNLEADED GASOLINE ONLY Fuel tank capacity: 15.0 L (3.96 US gal) (3.30 Imp.gal) Fuel reserve amount: 3.0 L (0.79 US gal) (0.66 Imp.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 7 maintenance costs. 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. EAU13630 Starter (choke) lever EAU13730 Steering lock 1 1.
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. EAU14230 Rider seat 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. 2 3 1. Bolt 2. Screw To install the rider seat 1.
INSTRUMENT AND CONTROL FUNCTIONS 2. Place the rider seat in the original position, and then tighten the bolts and screws. 1 2 EAU14281 Helmet holder This front fork is equipped with air valves for adjusting the spring rate. NOTE: Make sure that the seat is properly secured before riding. EWA10180 WARNING Always adjust both fork legs equally, otherwise poor handling and loss of stability may result. 3. Return the rider seat backrest to the original position.
INSTRUMENT AND CONTROL FUNCTIONS able at a Yamaha dealer. 5. Securely install the air valve caps. 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. 1. Front fork air valve cap 2. Front fork air valve 3. Check the air pressure in each fork leg with an air pressure gauge.
INSTRUMENT AND CONTROL FUNCTIONS EAU15083 Adjusting the shock absorber assemblies result. justment. Spring preload 1 (b) (a) 2 1 3 4 5 6 1. Spring preload adjusting ring 1. Shock absorber assembly Both shock absorber assemblies are equipped with a spring preload adjusting ring and a damping force adjusting knob. 7 ECA10100 8 CAUTION: Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.
INSTRUMENT AND CONTROL FUNCTIONS Damping force Damping force: Minimum (soft): 1 Standard: 1 Maximum (hard): 4 ● formance. Always have a Yamaha dealer service the shock absorbers. 2 EWA10230 1. Damping force adjusting knob 2. Position indicator To increase the damping force and thereby harden the damping, turn the adjusting knob on each shock absorber assembly in direction (a).
INSTRUMENT AND CONTROL FUNCTIONS EAU15271 V-Boost CAUTION: If the V-Boost operation cannot be heard when the main switch is turned on, ask a Yamaha dealer to inspect it. 1 3 5 6 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. 8 9 The sidestand is located on the left side of the frame.
INSTRUMENT AND CONTROL FUNCTIONS pair it if it does not function properly. EAU15321 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.
INSTRUMENT AND CONTROL FUNCTIONS 1 2 3 4 5 6 With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
PRE-OPERATION CHECKS EAU15603 Pre-operation check list ITEM CHECKS ● 1 Fuel ● ● 2 ● Engine oil ● ● 3 Final gear oil ● ● Coolant 4 ● ● ● ● 5 ● ● 6 Front brake ● ● ● ● 7 ● ● ● 8 ● Rear brake 9 ● ● ● ● Check fuel level in fuel tank. Refuel if necessary. Check fuel line for leakage. Check oil level in engine. If necessary, add recommended oil to specified level. Check vehicle for oil leakage. Check vehicle for oil leakage. Check coolant level in reservoir.
PRE-OPERATION CHECKS ITEM CHECKS ● ● Clutch ● ● ● ● Throttle grip Control cables ● ● ● ● ● Wheels and tires ● ● ● Brake and shift pedals Brake and clutch levers Centerstand, sidestand Chassis fasteners Instruments, lights, signals and switches Sidestand switch Battery ● ● ● ● ● ● ● ● ● ● ● ● ● ● 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.
OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 1 ● 2 3 4 ● 5 6 7 8 9 ● 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.
OPERATION AND IMPORTANT RIDING POINTS ● ● 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 not go off after starting with sufficient engine oil, have a Yamaha dealer check the electrical circuit.
OPERATION AND IMPORTANT RIDING POINTS EAU16671 Shifting 1 2 ● 3 4 5 6 7 8 9 1. Shift pedal Shifting gears lets you control the amount of engine power available for starting off, accelerating, climbing hills, etc. The gear positions are shown in the 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.
OPERATION AND IMPORTANT RIDING POINTS EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below. Shift up points: 1st → 2nd: 16 km/h (10 mi/h) 2nd → 3rd: 24 km/h (15 mi/h) 3rd → 4th: 32 km/h (20 mi/h) 4th → 5th: 40 km/h (25 mi/h) Shift down points: 5th → 4th: 20 km/h (12.5 mi/h) 4th → 3rd: 20 km/h (12.5 mi/h) 3rd → 2nd: 20 km/h (12.5 mi/h) 2nd → 1st: 20 km/h (12.
OPERATION AND IMPORTANT RIDING POINTS EAU17200 Parking 1 When parking, stop the engine, and then remove the key from the main switch. EWA10310 2 ● 3 4 5 ● 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 vehicle may overturn.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 PERIODIC MAINTENANCE 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.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 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. NOTE: If you do not have the tools or experience required for a particular job, have a Yamaha dealer perform it for you.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE ● 1 * Fuel line ● 2 * Fuel filter ● ● 3 Spark plugs 4 * Valve clearance 5 * Crankcase breather system 6 * Carburetor synchronization 7 * Idle speed ● ● ● ● ● ● ● ● 8 * Exhaust system ● ● 9 * Evaporative emission control system (For California only) ● ● Check fuel hoses for cracks or damage. Replace if necessary. Replace. Check condition.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU32183 General maintenance and lubrication chart INITIAL 1 No. ITEM ROUTINE 2 1 * Air filter element 2 * Battery 3 * Clutch 3 ● ● 4 ● ● 5 6 ● ● 4 * Front brake 5 * Rear brake 6 * Brake hoses ● ● 7 8 ● ● ● 9 7 * Wheels ● ● ● 8 * Tires ● ● ● Clean with compressed air. Replace if necessary. Check specific gravity and breather hose for proper operation. Check operation and fluid leakage. Correct if necessary.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE ● 9 * Wheel bearings ● ● 10 * Swingarm pivot bearings ● ● 11 * Steering bearings ● ● 12 * Chassis fasteners ● 13 Brake and clutch lever pivot shafts 14 Brake and shift pedal pivot shafts ● ● ● 15 * Centerstand and sidestand pivots ● Check bearings for smooth operation. Replace if necessary. Check bearing assemblies for looseness. Moderately repack with lithium-soap-based grease. Check bearing assemblies for looseness.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 4000 mi (7000 km) or 6 months Check operation and replace if necessary. Check operation and for oil leakage. Replace if necessary. Check operation and for oil leakage. Replace if necessary. Change (warm engine before draining). √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ √ ● Replace. √ ● Check hoses for cracks or damage. Replace if necessary. Change with ethylene glycol anti-freeze coolant every 24 months.
PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months Check operation and free play. Adjust the throttle cable free Throttle grip hous24 * play if necessary. √ √ ing and cable ● Lubricate the throttle grip housing and cable.
PERIODIC MAINTENANCE AND MINOR REPAIR 3. Push down on the rear of the cowling until it locks in place. 4. Remove the key from the lock. EAU18721 Removing and installing the cowling and panels 1 2 3 The cowling and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the cowling or a panel needs to be removed and installed. EAU19180 Panel A 1. Unlock. 4 2. Pull the cowling off as shown. To remove the panel 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19210 Panel B To remove the panel Remove the screws, and then take the panel off. EAU19543 Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic maintenance and lubrication chart. In addition, the condition of the spark plugs can reveal the condition of the engine.
PERIODIC MAINTENANCE AND MINOR REPAIR trode erosion and excessive carbon or other deposits, and replace it if necessary. 1 Specified spark plug: NGK/DPR8EA-9 DENSO/X24EPR-U9 2 3 4 To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 5 6 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU19871 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The engine oil should be between the minimum and maximum level marks. 2. Place an oil pan under the engine to collect the used oil. 3.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 1. Engine oil drain bolt 4 5 NOTE: Skip steps 4–6 if the oil filter cartridge is not being replaced. 6 4. Remove the oil filter cartridge with an oil filter wrench. 7 1. Oil filter cartridge 2. Oil filter wrench 1. O-ring NOTE: An oil filter wrench is available at a Yamaha dealer. 5. Apply a thin coat of engine oil to the O-ring of the new oil filter cartridge. 8 9 6-12 NOTE: Make sure that the O-ring is properly seated. 6.
PERIODIC MAINTENANCE AND MINOR REPAIR Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 3.50 L (3.70 US qt) (3.08 Imp.qt) With oil filter cartridge replacement: 3.80 L (4.02 US qt) (3.34 Imp.qt) ECA11620 1. Torque wrench Tightening torque: Oil filter cartridge: 17.5 Nm (1.75 m·kgf, 12.7 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) 8.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20000 Final gear oil 1 2 3 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 vehicle. In addition, the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrication chart. 2. Remove the oil filler bolt, and then check the oil level in the final gear case. NOTE: The oil level should be at the brim of the filler hole.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU20070 Coolant 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. NOTE: The coolant should be between the minimum and maximum level marks. EAU20241 To check the coolant level 1. Place the vehicle on the centerstand and hold it in an upright position. 2. Remove cowling A. (See page 6-8.
PERIODIC MAINTENANCE AND MINOR REPAIR ● coolant temperature in the radiator. If the engine overheats, see page 6-40 for further instructions. 1 EAU20392 2 3 4 5 To change the coolant 1. Place the vehicle on the centerstand and let the engine cool if necessary. 2. Remove cowling A and panel A. (See page 6-8.) 3. Place a container under the engine to collect the used coolant. 4. Remove the radiator cap. 1. Radiator cap 1. Water pump drain bolt 5.
PERIODIC MAINTENANCE AND MINOR REPAIR engine. drain plug covers. NOTE: Check the rubber plugs for damage and replace them if necessary. 1. Rubber coolant drain plug 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. Tightening torque: Water pump drain bolt: 43 Nm (4.3 m·kgf, 31 ft·lbf) 12.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 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. EAU20510 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR become excessively worn. 6. Install the air filter case cover by installing the screws. 7. Install the cowling. EAU21271 Carburetors 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. EAU21381 Checking the throttle cable free play 2 3 4 1.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU21401 1 2 3 EAU32380 Valve clearance Tires 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. To maximize the performance, durability, and safe operation of your motorcycle, note the following points regarding the specified tires.
PERIODIC MAINTENANCE AND MINOR REPAIR and check the condition and pressure of your tires. NEVER OVERLOAD YOUR VEHICLE. Make sure that 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 vehicle. Operation of an overloaded vehicle could cause tire damage, an accident, or even injury.
PERIODIC MAINTENANCE AND MINOR REPAIR 1 2 3 4 5 6 7 8 9 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 high-speed 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22011 Accessories and replacement parts been approved by Yamaha. EAU22072 Clutch lever 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22092 Adjusting the brake lever free play 3. Tighten the locknut. ● 1 2 ● 3 4 5 6 7 8 9 1. Locknut 2. Brake lever free play adjusting screw 3. Brake lever free play The brake lever free play should measure 2.0–5.0 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 screw in direction (a).
PERIODIC MAINTENANCE AND MINOR REPAIR EAU22311 Checking the front and rear brake pads EAU22680 Checking the brake and clutch fluid levels Clutch Front brake 2 3 1. Minimum level mark 1. Brake pad wear indicator 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.
PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 1 2 3 4 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 ● 5 6 ● 7 8 9 ● ● ● of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23111 Checking and lubricating the cables Checking and lubricating the throttle grip and cable 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. The operation of the throttle grip should be checked before each ride.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) EAU23211 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23250 Lubricating the rear suspension The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart. EAU23271 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 1 2 3 4 5 6 7 EAU23290 Checking the steering Checking the wheel bearings 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23351 Battery straight up when checking the electrolyte level. lead and the starter motor lead from the starter motor relay. 2. Check the electrolyte level in the battery. NOTE: The electrolyte should be between the minimum and maximum level marks. 2 3 4 1. Battery 2. Battery breather hose 3. Pass through the cable guide. A poorly maintained battery will corrode and discharge quickly.
PERIODIC MAINTENANCE AND MINOR REPAIR 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. ● 1 ● 2 ● 3 4 5 6 7 8 9 1. Ignition coil assembly 2.
PERIODIC MAINTENANCE AND MINOR REPAIR 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. EAU23570 Replacing the fuses The main fuse box is located under the rider seat. (See page 3-9.) ECA10600 1. Positive battery lead (red) 2. Starter motor lead (black) 14. Connect and tighten the negative battery lead to the battery. 15. Install the rider seat.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU23780 1 2 3 4 5 6 7 8 9 Replacing the headlight bulb Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Radiator fan fuse: 10.0 A Ignition fuse: 10.0 A 1. Headlight fuse 2. Signaling system fuse 3. Ignition fuse 4. Radiator fan fuse 5. Spare fuse If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2.
PERIODIC MAINTENANCE AND MINOR REPAIR 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. EAU24281 Replacing a turn signal light bulb or the tail/brake light bulb 1. Remove the lens by removing the screws. 2 3 1. Headlight bulb holder 4 3.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel EAU24430 To remove the front wheel 1 EWA10820 2 ● ● 3 1. Tail/brake light bulb 4 5 6 7 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. 4. Install the lens by installing the screws. ECA10680 8 9 CAUTION: Do not overtighten the screws, otherwise the lens may break.
PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the brake calipers by installing the bolts. NOTE: Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs. 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. 5. Take the motorcycle off the centerstand so that the front wheel is on the ground. 6.
PERIODIC MAINTENANCE AND MINOR REPAIR 2 7. Pull the wheel to the right to separate it from the final gear case, and then remove it. 3 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. 1 ECA11180 1 2 5 4 3 1. Rear wheel axle pinch bolt 4 5 6 2. Place the motorcycle on the centerstand. 3. Remove the brake caliper by removing the bolts. 4.
PERIODIC MAINTENANCE AND MINOR REPAIR ing the bolts. NOTE: Make sure that there is enough space between the brake pads before installing the brake caliper onto the brake disc. 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.
PERIODIC MAINTENANCE AND MINOR REPAIR EAU25941 Troubleshooting charts Starting problems or poor engine performance EWA10840 1 2 3 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. 4 2. Compression 5 There is compression. Check the ignition. There is no compression.
PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 ● ● 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.
MOTORCYCLE CARE AND STORAGE EAU26060 Care 1 2 3 4 5 6 7 8 9 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.
MOTORCYCLE CARE AND STORAGE 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.
MOTORCYCLE CARE AND STORAGE EAU26230 NOTE: Consult a Yamaha dealer for advice on what products to use. 1 2 3 4 5 6 7 8 9 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover. ECA10810 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.
MOTORCYCLE CARE AND STORAGE install the spark plugs and the spark plug caps. EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. than 0 °C (30 °F) or more than 30 °C (90 °F)]. For more information on storing the battery, see page 6-31. NOTE: Make any necessary repairs before storing the motorcycle. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/ centerstand.
SPECIFICATIONS EAU2633D Dimensions: 1 2 3 4 5 6 Overall length: 2300 mm (90.6 in) Overall width: 795 mm (31.3 in) Overall height: 1160 mm (45.7 in) Seat height: 765 mm (30.1 in) Wheelbase: 1590 mm (62.6 in) Ground clearance: 145 mm (5.71 in) Minimum turning radius: 2900 mm (114.
SPECIFICATIONS Manufacturer/model: DENSO/X24EPR-U9 Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) Clutch: Clutch type: Wet, multiple-disc Transmission: Primary reduction system: Spur gear Primary reduction ratio: 87/49 (1.776) Secondary reduction system: Shaft drive Secondary reduction ratio: 21/27 × 33/09 (2.852) Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 43/17 (2.529) 2nd: 39/22 (1.773) 3rd: 31/23 (1.348) 4th: 28/26 (1.077) 5th: 26/28 (0.
SPECIFICATIONS Rear brake: 1 2 3 4 Type: Single disc brake Operation: Right foot operation Recommended fluid: DOT 4 Front suspension: Type: Telescopic fork Spring/shock absorber type: Coil-air spring/oil damper Wheel travel: 140.0 mm (5.51 in) Rear suspension: 5 6 7 8 9 Type: Swingarm Spring/shock absorber type: Coil spring/oil damper Wheel travel: 100.0 mm (3.
CONSUMER INFORMATION EAU26351 Identification numbers EAU26390 Key identification number EAU26400 Vehicle identification number 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. KEY IDENTIFICATION NUMBER: 2 3 1.
CONSUMER INFORMATION EAU26530 Model label 1 2 3 4 5 6 7 1. Model label The model label is affixed under cowling A. (See page 6-8.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
CONSUMER INFORMATION EAU26550 Reporting safety defects If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
CONSUMER INFORMATION EAU26560 Motorcycle noise regulation 1 2 3 4 5 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 a
CONSUMER INFORMATION EAU26632 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your vehicle 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.
CONSUMER INFORMATION Maintenance interval 1 2 3 Date of service Servicing dealer name and address Mileage 32000 mi (49000 km) or 48 months 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months 4 5 6 7 8 9 9-6 Remarks
CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
CONSUMER INFORMATION 1 2 3 4 5 6 7 8 9 9-8
CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. 1 2 3 A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
INDEX A F Accessories and replacement parts ........6-23 Air filter element, cleaning .......................6-18 B Battery .....................................................6-31 Brake and clutch fluid levels, checking ....6-25 Brake and clutch fluids, changing ............6-26 Brake and clutch levers, checking and lubricating ..............................................6-28 Brake and shift pedals, checking and lubricating ..............................................6-27 Brake lever ..............
INDEX Troubleshooting charts ........................... 6-40 Turn signal indicator light .......................... 3-1 Turn signal light bulb or tail/brake light bulb, replacing ............................................... 6-35 Turn signal switch ..................................... 3-4 V Valve clearance ...................................... 6-20 V-Boost ................................................... 3-14 Vehicle identification number .................... 9-1 W Warranty, extended..............
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005.5–0.
