Yamaha EAU10041 manual

PRINTED IN JAPAN 2004.04-0.3 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 5GK-28199-15 LIT-11626-18-18 VMX12T(C) OWNER’S MANUAL[...]

EAU10041 U5GK15E0.book P age 1 Tuesday, April 13, 2004 3:52 PM[...]

INTRODUCTION EAU10080 Congr atula tions on your purcha se of the Ya maha VM X12. This mo del is th e result of Yamah a’s vast experience i n th e pro- ductio n of fine sporting, touring , and paceset ting r acing ma chines. It r epres ents th e high degree o f craf tsmansh ip and reli- abili ty tha t have made Ya maha a lead er in th ese fi elds.[...]

IMPORTANT MANUAL INFORMATION EAU1013 0 Parti cularl y import ant info rmati on is disti nguis hed in this manual by t he follo wing nota tions: NOTE: ● This ma nual sho uld be co nsid ered a pe rmanent part of this motorc ycle and should remain w ith it e ven if th e motorc ycle is subs equently so ld. ● Yamaha continually s e eks a dvancem ent[...]

IMPORTANT MANU AL INFORMATION AND UNTIL YOU HAVE BE EN TRAINED IN SAFE AN D PROPER RIDIN G TECHNIQUE S. REGULAR INS PECTIONS AND CAREFUL MAINTENAN CE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPAB ILITIES AND THE RELIA BILITY OF THIS MOTORCYCLE. U5GK15E0.book P age 2 Tuesday, April 13, 2004 3:52 PM[...]

IMPORTANT MANUAL INFORMATION EAU10192 VMX12 T(C) OW N E R ’ S MANU AL ©2004 by Y amaha Motor Corporation, U .S.A. 1st editi on, April 200 4 All rights reserved. Any reprinting or unauthorized use without th e written permission of Y amaha Motor Corporation, U.S.A. is expressl y pr ohibited. Printed in Japan. P/N LIT -1162 6-18-1 8 AFFIX DEALER L[...]

TABLE OF CONTENTS SAFETY INFORMATION ............. ..... 1-1 Location of important lab els ........... 1-5 DESCRIPTION ............ ...................... 2-1 Left view ............... ...................... ..... 2-1 Right view .................. ................. ..... 2-2 Controls a nd instrumen ts ................2-3 INSTRUMENT AND CONTROL FUNC[...]

TABLE OF CONTENTS Checking the whee l bearings .......6-30 Battery ....... ...................... .............6-30 Replacing the fuses .................... ..6-33 Replaci ng the hea dlight bu lb ........6-34 Replaci ng a turn s ignal li ght bulb or the tail /brake light bul b ..........6-35 Front wheel ...................... .............6-36 Rear[...]

1-1 1 SAFETY INFORMATION EAU10270 MOT ORCYC LES ARE SINGLE TRAC K VE HIC LES. THEIR SAF E USE AND OPERATION AR E DEPEN- DENT UPON THE USE OF PROPER RID ING T ECH NIQU ES A S WEL L AS THE EXPERTISE OF THE OPERA- TOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIRE- MENTS B EFORE RIDING THIS MOTOR CYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUC[...]

SAFETY INFORMATION 1-2 1 turn du e to EXCESSI VE SPEED or und ercorn ering ( insuffic ient lea n angle for th e spee d). • Alway s obey the spee d limit and never trav el fast er than war rant- ed by ro ad an d traffic conditi ons. • Alway s signal be fore turn ing or chan ging lanes. Mak e su re tha t othe r motorists can see you. ● The post[...]

SAFETY INFORMATION 1-3 1 Loadin g The to tal weig ht of th e operat or, pas- senger, acce ssories and ca rgo must not exc eed the maxi mum load lim it of 215 kg (474 lb) (CAL)(ZAF) / 216 kg (476 lb) (U49). When loadin g w ith in this wei ght lim it, kee p the fo llowin g in min d: ● Cargo and ac cess ory wei ght shoul d be kept as low and cl ose [...]

SAFETY INFORMATION 1-4 1 Gasoline and exhau st gas ● GASOL INE IS HIG HLY FLAMM A- BLE: • Alway s turn th e engin e off whe n refuelin g. • Take care no t to spil l any gaso- line on the e ngine o r exhaus t syste m when ref ueling. • Never r efuel while smoking or in the vici nity of an op en fl ame. ● Never start th e engin e or let it [...]

SAFETY INFORMATION 1-5 1 EAU10381 Location of important labels Plea se read the f ollowing impor tant l abels c arefu lly befo re ope ratin g this v ehicle . U5GK15E0.book P age 5 Tuesday, April 13, 2004 3:52 PM[...]

SAFETY INFORMATION 1-6 1 1 3 2 CALIFORNIA ONL Y 4 5 00 U5GK15E0.book P age 6 Tuesday, April 13, 2004 3:52 PM[...]

DESCRIPTI O N 2-1 2 EAU10410 Left view 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 spr ing preload adjusting ring (page 3-11) 7. Shock absorber assembly damping force adjusting k nob (page 3-11) 8. Helmet h[...]

DESC RIPTION 2-2 2 EAU1042 0 Right view 1. Fuel tank cap (page 3-6) 2. Batter y (page 6-30) 3. Coolant r eservoir (page 6-14) 4. Front brak e fluid reser voir (page 6-25) 5. Main switch (page 3-1) 6. Radiator cap (page 6-14) 7. Radiator (page 6-14) 8. Engine oil filter car tridge (page 6-11) 9. Engine oil level chec k window (page 6-11) 10.Brake pe[...]

DESCRIPTI O N 2-3 2 EAU10430 Controls and instruments 1. Clutch lev er (page 3-5) 2. Left handlebar switches (page 3-3) 3. Speedometer un it (page 3-2) 4. Right handlebar s wit ches (page 3-3) 5. Brake lev er (page 3-5) 6. Throttle grip (page 6-19) 7. T achom eter (page 3-3) 8. Coolant temperature gauge (page 3-3) U5GK15E0.book P age 3 Tuesday, Apr[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-1 3 EAU10450 Main s witch The ma in switch control s the ig nition and lig hting systems. The vari ous main switch po sitions are descri bed below . EAU10510 ON All elec trical system s are su pplied wi th power, and the h eadligh t, meter light- ing, ta illight and posit ion ligh ts come on, and th e engi ne can[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-2 3 EAU11090 High beam indi cator light “ HIGH BEAM ” This i ndicato r lig ht comes on when the high beam o f the h eadl ight is s witched on. EAU32330 Oil leve l warn ing light “ OIL LEVEL ” This w arning light comes on whe n the engine oil level is low. The el ectri cal circ uit of the w arning light can[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-3 3 EAU11851 Tachometer The electr ic tach ometer allows t he rid er to mon itor the engine speed and keep it within the idea l power rang e. CAUTION: ECA10031 Do not operate the engine in the ta- chometer red zone. Red zone: 9000 r/min and a bove EAU12171 Coolant temperature gauge With the key in the “ ON ” [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-4 3 EAU12410 Dimmer switch “ LIGHTS ” Set the swit ch to “ HI ” for t he high beam and to “ LO ” for the low beam. EAU12420 Turn signal s witch “ TURN ” To sign al a righ t-hand turn, pu sh this switch to the righ t. To si gnal a left-ha nd turn, push t he sw itch to the le ft. Wh en rele ased, the[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-5 3 EAU12820 Clutch lever The clu tch le ver is located at the left handle bar gr ip. To diseng age the clutc h, pull the le ver to ward the h andl e- bar gr ip. To e ngage the clutc h, rele ase the lev er. Th e le ver sh ould be pulle d rapid ly and rel eased slowly fo r smoo th clutc h operat ion. The c lutch l[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-6 3 EAU12941 Brake pe dal The brake p edal i s on t he righ t side of the mo torcycl e. To apply t he rear brak e, pres s down on th e brake pedal . EAU13060 Fuel tank cap To remove the fuel tank c ap 1. Pu sh the lever s on th e left a nd righ t side of the r ider se at backres t as sho wn and s lide the r ider s[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-7 3 EAU13210 Fuel Make s ure that there is suffi cient fu el in the tank . Fill the fuel tank to the botto m of the f iller t ube as shown . W ARNING EWA10880 ● Do not overfill the fuel tank, oth- erwi se it may overflow when th e fuel warms up and expands. ● Avoid spill ing fuel on the hot en- gine. CAUTION:[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-8 3 EAU13630 Starter (chok e) lever Star ting a col d engi ne req uires a richer air-f uel mixt ure, w hich is s upplied by the starter (choke). Move the lever i n direction (a) t o turn on the starter (choke). Move the lever in direction (b) to tu rn off the starter (choke). EAU13730 Steering lock To lock the ste[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-9 3 EAU14230 Rider seat To remove t he rider seat 1. Releas e the rider seat backre st by pushi ng the le vers on th e left and righ t side as show n, an d then s lide the back res t forward. 2. Remove the bolts an d screws, a n d then p ull th e rider seat off. To ins tall the rider seat 1. In sert the proje cti[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-10 3 EAU14281 Helmet holder To op en the helm et hold er, in sert the key int o the lock, an d then turn the key as shown . To lock the helmet holder, pl ace i t in th e origi n al po sition, and the n remo ve the key. W ARNING EWA10160 Never r ide with a hel met atta ched to the helm et holder, sinc e the helme t[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-11 3 4. T o inc rease the sp ring rate an d there by har den the s uspen sion, in- crease the air press ure wi th an ai r pump o r com pressed air. To de- crease the spring rate an d thereby soften th e suspen sion, de crease the ai r pre ssure by pus hing e ach valve st em dow n. CAUTION: ECA10090 Never ex ceed [...]

INSTRUMENT AND CONTROL FUNCTIONS 3-12 3 NOTE: ● Alig n the bo ttom ed ge of the ad- justi ng ring wi th the ap propr iate setti ng on the sho ck absorbe r. ● Use the s pecia l wrenc h incl uded in the o wner ’ s tool kit to make th is ad- justme nt. Damping force To incr ease the da mping fo rce and ther eby hard en the da mping, tur n the ad[...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-13 3 EAU15270 V-Boost The V-Bo ost is a vital par t of the engi ne and requ ires ver y soph istica ted adjus t- ment. A dju stment should be le ft to a Yamaha deale r who has the pr ofes- sional knowledge a n d e xperie nce to do so. CAUTION: ECA10170 The V- Boost w as se t at t he Yam aha factory after many test[...]

INSTRUMENT AND CONTROL FUNCTIONS 3-14 3 below and h ave a Yamaha dealer re- pair it if it does not function proper- ly. EAU15321 Ignition circuit cut-off system The igni tion circ uit cut -off s ystem (com- prising th e sidestand switch, clutch switch and neutr a l swi tch) has th e fol- lowi ng fu nctions . ● It preven ts sta rting whe n the tr [...]

INSTRUMENT A ND CONTROL FUNCTIONS 3-15 3 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is tur ned on. 3. T ur n the ke y on. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Mov e the sidestand up. 7. K eep th[...]

PRE-OPERATION CHE CKS 4-1 4 EAU15591 The c onditi on of a veh icle is th e owner ’ s re sponsi bility . Vital co mpon ents can s tart to de teriora te quic kly and un expec tedly, even i f the veh icle re main s unused (for exa mple, as a resu lt of ex posure to the elem ents) . Any da mage, fl uid lea kage or l oss of tir e air pressu re co uld [...]

PRE-OPERATION CH ECKS 4-2 4 EAU15602 Pre-opera tion check list ITEM CHECKS P A GE Fuel • Check fuel l evel in fuel tank. • Refuel if necessary . • Check fuel l ine for leakage. 3-7 Engin e oil • Check oil lev el in engine. • If necessar y , add reco mmended oil to specified lev el. • Check v ehicle for oil leak age. 6-11 Final gear oi l[...]

PRE-OPERATION CHE CKS 4-3 4 Clutch • Check operation. • If soft or spong y , hav e Y a maha dealer b leed hydrauli c system. • Check fl uid lev el in reser voi r. • If necessar y , add recommended fluid to specified le vel. • Check h ydraulic system for leakage. 6-23, 6-25 Thr ottle grip • Make sure that operation is smooth. • Check c[...]

OPERATION AND IM PORTANT RIDING POINTS 5-1 5 EAU15950 W ARNING EWA10270 ● Become thoroughly familiar with all operating c ontrols and their functions before riding. Consult a Yamaha dealer re- garding any control or function that you do not thoroughly un- derstand. ● Never start the engine or oper- ate it in a cl osed ar ea for any length of ti[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-2 5 is pushed, and they should go off whe n the start swi tch is re- leas ed. ● If the oil le vel wa rning light fl ick- ers or remains on after sta rting, immediately stop the engine, and then check the engine oil level an d the vehicl e for o il leak - age. If n ecess ary, ad d engin e oil , and th en ch[...]

OPERATION AND IM PORTANT RIDING POINTS 5-3 5 EAU16640 Starting a warm engine Follow t he same proce dure as fo r star t- ing a co ld engine with t he excep t ion that t he star ter ( choke ) is n ot requ ired when th e eng ine is warm. EAU16671 Shifting Shifti ng gear s lets you c ontrol th e amount of engine po wer ava ilable for starti ng off, ac[...]

OPERATION AND IMPORTANT RIDING P OINTS 5-4 5 4. At the re comme nded shift po ints sho wn in the fo llow ing tabl e, cl ose the thr ottle, and at the same ti me, quickl y pull th e clutch lever in. 5. Sh ift t he tran smis sion i nto s econd gear. (M ake su re not t o shift the transm ission int o the neut ral posi- tion.) 6. Open the thrott le par[...]

OPERATION AND IM PORTANT RIDING POINTS 5-5 5 CAUTION: ECA10331 After 1000 km (600 mi) of operation, the engine oil and final gear oil must be changed, and the oi l filter car- trid ge or el ement repl aced. 1600 km (1000 mi) and beyon d The vehi cle can now be operated nor- mally . CAUTION: ECA10310 ● Keep the engine speed out of the tachometer r[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-1 6 EAU17231 Safety is an obliga tion of the o wner . Pe- riod ic inspe ction , adju stment and lubr i- cation will keep your vehi cle in th e safest and most eff icient co ndition po s- sible. The mos t impo rtant poi nts of motor cycle inspectio n, adjus tment, an d lubri cation a re explai ned on t he fo[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-2 6 you in the perform ance o f prev entiv e mainte nance a nd mino r repa irs. How- ever , addition al tool s such as a tor que wrench may be n ecessary to perf orm cert ain main tenance wo rk corr ectly . NOTE: If you do not have t he tools or experi- ence re quired for a par ticular job, have a Yam aha [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-3 6 EAU17600 Periodi c mainte nance char t for the e mission c ontrol sy stem * Since the se item s requir e special tools, data and tech nical ski lls, have a Ya maha dea ler per form the service. No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 month s 8000 mi [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-4 6 EAU32182 General maintenance and lubrication chart No. ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months 8000 mi (13000 km) or 12 months 12000 mi (19000 km) or 18 mo nths 16000 mi (25000 km) or 24 months 20000 mi (31000 km) or 30 months 1 * Air filter elem[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-5 6 9 * Whe el bea rings • Check bearings f or smooth oper- ation. • Replace if necessary . √√√√√ 10 * Swingar m piv ot beari ngs • Check bearing assemblies f or looseness. • Moderately repack with lithium- soap-based grease. √ Repack. 11 * Steeri ng bearings • Check bearing assemblies[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-6 6 * Since th ese items re quire speci al tools, data an d technical skills , have a Yamaha de aler perfo rm the service . 18 * Shock absorber as- semb lie s • Check operation and for oil leak- age. • Replace if necessar y . √√√√√ 19 Engine oi l • Change (warm engine before draining). √?[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-7 6 NOTE: From 24 000 mi ( 37000 km ) or 36 m onths, repeat th e mainte nance interval s starti ng from 8000 mi (1 3000 km ) or 12 mon ths. EAU17660 NOTE: ● The ai r filte r need s mor e freque nt s ervice if yo u are riding in unu suall y wet o r dusty area s. ● Hydrau lic brake and clut ch syst ems ?[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-8 6 EAU18721 Removing and installing the cowling and panels The cowl ing and pane ls shown need to be remo ved to pe rform some of th e main tenanc e jobs de scribe d in thi s chapte r. Refer to this secti on each tim e the co wling o r a pa nel needs to be r e- moved and instal led. EAU19120 Cowling A To [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-9 6 EAU19210 Panel B To rem ove th e pane l Remove the screws , and t hen ta ke the panel of f. To instal l the panel Plac e the pa nel in t he orig inal p osition , and the n instal l the screw s. EAU19543 Checking the spark plugs The s park p lugs are import ant engi ne compon ents, w hich ar e easy to ch[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-10 6 3. Check ea ch spark pl ug for el ec- trode e rosion and e xcessive car - bon or othe r depo sits, and re place it if necessary. To in stall a spark plug 1. Meas ure t he spar k plug gap with a wire thickne ss gauge a nd, if nec- essa ry, ad just t he ga p to spe cific a- tion. 2. Clea n the s urface [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-11 6 EAU19871 Engine oil and oil filter cartridge The engi ne oil level should b e checke d bef ore each ri de. In addi tion, the oil must be ch anged a nd th e oil f ilter car- trid ge replac ed at th e inter vals s peci- fied i n the periodi c main tenanc e and lubri cation ch art. To check the engine oil[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-12 6 NOTE: Skip st eps 4 – 6 if the oil fi lter ca rtridg e is not bei ng re placed. 4. Re move th e oil filter cartridge with an oil filter wrench. NOTE: An oil fi lter wren ch is av ailab le at a Yamaha dealer. 5. Appl y a thin coa t of engi ne oil to the O-r ing of the ne w oil filter ca r- tridge. N [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-13 6 CAUTION: ECA11620 ● In order to prevent clutch slip- page (since the e ngine oil also lubricates the clutch), do not mix an y chemi cal ad ditive s. Do not us e oils with a diesel spec i- fication of “ CD ” or oils of a high- er qu alit y than specif ied. In addition, do not use oils labeled “ [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-14 6 2. Re move th e oil fill er bolt, an d then check th e oi l level i n the fi nal ge ar case. NOTE: The o il le vel shou ld be at the brim of the fille r hole. 3. If the oil is below the brim of the fill - er ho le, ad d suffic ient o il of the rec- ommend ed type to raise it to the correct level . To [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-15 6 NOTE: The c oolant shoul d be betwe en the mini mum and max imum level marks . 4. If th e coolan t is at or belo w the mini mum le vel mar k, remo ve the coolan t res ervoir cap an d add coolan t to the m aximu m le vel mark. 5. Install the cool ant reservo ir cap and the cow ling. CAUTION: ECA10470 ?[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-16 6 5. Turn t he coola nt drai n cock, mak - ing s ure to a lign th e “ ON ” with the posi tion indi cator . 6. Remove the water pump dra in bolt to dr ain the water pump h ousin g. 7. Remove the cy linder d rain plug cove rs on t he outs ide o f the c ylin- der b locks by removing the screws. 8. Remo[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-17 6 NOTE: Check the ru bber plu gs for da mage and r eplace them if necessa ry. 12. Turn the cool ant dr ain cock , mak- ing su re to al ign the “ OFF ” with the position indi cator. 13. Pour th e reco mmende d cool ant into t he reser voir to the max imum level, and the n install the cap. 14. Pour th [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-18 6 EAU20510 Cleaning the air filter elem ent The a ir fi lter e lemen t shou ld be clea ned at the inte rval s specif ied in the period ic mainte nanc e and lub ricati on char t. Clean t he air filter el ement m ore fre- quen tly if yo u are ridi ng in unu suall y wet or dusty a reas. 1. Remove cowling A[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-19 6 EAU21270 Adjusting the carburetors The carbur etors a re im portan t parts of the engine and em issi on con trol sys- tem , whic h requ ire v ery so phis tica ted adjust ment. The refor e, all c arburetor adjust ments s hould be le ft to a Y a mah a deal er, who ha s the necessary profes - sion al kno [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-20 6 EAU32380 Tires To max imize t he pe rforman ce, dur abil- ity, an d safe operati on of your motor- cycle, no te the follo wing po ints regar ding th e specifi ed ti res. Tire air pressure The tire air p ressure should be ch ecked and, if necessar y, adju sted befo re each ride. W ARNING EWA10500 ● T[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-21 6 if the tire has a na il or gl ass frag ments in it, or if the s idewall is c racked, con- tact a Yam aha de aler imme diat ely and have the tire repl aced. W ARNING EWA10580 ● It is dangerous to r ide with a worn-out tire. When a tire tre ad begins to show crosswise lines, have a Yamaha dealer replac[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-22 6 EAU21980 Cast wheels To max imize t he pe rforman ce, dur abil- ity, an d safe operati on of your motor- cycle, no te the follo wing po ints rega rding th e speci fied whee ls. ● The wh eel ri ms shou ld be checked for cracks, be nds, warpage or damage befo re each ride. If any damage is found , hav[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-23 6 any consequences caused by the use of items which have not been approved by Yamaha. EAU22071 Clutch leve r free play Sinc e this mo del is eq uipped with a hy- draul ic clut ch, adj ustin g the clutc h leve r free p lay is no t needed . Howeve r, it is necessar y to check the cl utch fluid l evel and c[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-24 6 W ARNING EWA10630 ● After adjustin g the bra ke lever free play, che ck the f ree play and ma ke sure t hat th e brake is working properly. ● A soft or spongy feeling in the brak e lever can indi cate t he presence of air in the hydraulic syst em. I f th ere is air in the h y- draul ic system, hav[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-25 6 EAU22680 Checking the brake and clutch fluid level s Front brake Rear b rake Clutch Insuff icient brake fluid may al low air t o enter the br ake or c lutch system s, pos - sibly causing them to becom e ineff ec- tive. Befor e ridin g, check that the b rake f luid is above the minimu m level mar k and [...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-26 6 sign ifican tly l ower t he bo iling point of the fluid and ma y result in vapor lock. ● Brake fl uid may deterio rate paint- ed su rface s or plast ic part s. A l- ways clea n up spille d fluid immedia tely. ● As the br ake pads wear, it is nor- mal fo r the br ake flui d leve l to gr ad- ually g[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-27 6 EAU23110 Checking and lubricating the thro ttle grip and cable The op eratio n of the thro ttle grip sh ould be check ed before each ri de. I n addi- tion , the cable s hould be lubri cated or repl aced at the inte rval s speci fied in the perio dic mai ntena nce chart. EAU23131 Checking and lubricatin[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-28 6 EAU23140 Checking and lubricating the brake and clutch levers The o peratio n of th e brake and clut ch levers sh ould be c hecked before each ride, and the leve r piv ots sh ould b e lu - bricate d if nec essary . EAU23210 Checki ng and lubricat ing the centerstand and sidestand The op eratio n of th[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-29 6 EAU23271 Checking the front fork The c ondit ion an d opera tion of the f ront fork must be che cked as f ollows at the inter vals sp ecifi ed in the per iodic main- ten ance and lu bric ation ch art. To check the condition W ARNING EWA10750 Securely support the vehicle so that there is no danger of it[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-30 6 EAU23290 Checki ng the whe el bearings The f ront an d rear whe el beari ngs must be chec ked a t the int erval s spe cifie d in the pe riodi c mainte nance and lubr ica- tion ch art. If t here i s play in the wh eel hub or if th e wheel do es not turn smoot hly, h ave a Ya maha de aler ch eck the w h[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-31 6 NOTE: Make sure that th e veh icle is posi tioned stra ight up whe n chec king the el ectro - lyte l evel. 2. Che ck the el ectro lyte leve l in the batter y. NOTE: The electro lyte s hould be bet ween the mini mum and max imum level marks . 3. If t he elec trolyt e is at or below the minimu m lev el m[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-32 6 • INTERNAL: Drink large quan- tities of water or milk and im- mediate ly call a phys ician. • EYES: Flush wi th water for 15 minutes and seek prompt medical attention. ● Batteries produce explosive hy- drogen gas. Therefore , keep spar ks, fla mes, cig aret tes, etc ., away from the battery and [...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-33 6 4. Af ter in stal lation , make sure t hat the b attery leads are pr operly con- nec ted to th e batter y termina ls and that the br eather ho se is pr oper ly rou ted, in go od conditio n, and n ot obst ructe d. CAUTION: ECA10600 If the breather hose is positioned in such a way th at the f rame is ex-[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-34 6 CAUTION: ECA10640 Do not use a fuse of a higher amper- age rating than recommended to avoid causing extensive damage to the ele ctric al syst em an d possi bly a fire. 3. Turn the ke y to “ ON ” and tur n on the el ectric al cir cuit in quest ion to chec k if the devic e opera tes. 4. If the fus e[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-35 6 W ARNING EWA10790 Headlight bulbs get very hot. There- fore, keep fla mmable p roducts a way from a lit headlight bulb, and do not touch the bulb until it has cooled down. 4. Pl ace a new head light bulb i nto po- sition, a nd then secure it with the bulb holde r. CAUTION: ECA10660 Do not touch the gla[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-36 6 EAU24360 Front wheel EAU24430 To remove the f ront wheel W ARNING EWA10820 ● It is adv isable to have a Yamah a deale r serv ice the wheel. ● Securely support the motor- cycle so that th ere is no danger of it falling over. 1. Place t he moto rcycle on the cen- terstan d. 2. Disconn ect the spee d[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-37 6 4. Insta ll the bra ke calipers by in stall- ing t he bo lts. NOTE: Make su re that the re is en ough space betwe en the brak e pads before inst all- ing the brake cal ipers on to the bra ke discs. 5. T ake the m otorcycl e off th e cent er- stand s o that the fro nt whe el is on the gr ound. 6. Ti ght[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-38 6 5. W hile su pport ing the rear wheel, pull the whee l axle out . 6. Re move th e brake c aliper b racket and spac er. 7. Pull the wheel to the r ight t o sepa- rate it from the fi nal gear case, an d then r emove it. CAUTION: ECA11180 Do not push the brake pedal after the w heel ha s been r emoved to[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-39 6 8. Ins tall t he brak e torq ue rod cotter pin. W ARNING EWA10830 Always use a new c otter pin. EAU25870 Troubleshooting Althou gh Yam aha motor cycles recei ve a thor ough i nspec tion b efore shipm ent from th e factory , trouble ma y occur dur- ing op eration. An y pro blem in the f uel, compress io[...]

PERIODI C MAINTENA NCE AND MINOR REP AIR 6-40 6 EAU25941 Troubleshooting charts Starting problems or poor engine performance W ARNING EWA10840 Keep away open fla mes and do not sm oke while checking or working on the fuel sys tem. Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fu[...]

PERIODI C MAINTENAN CE AND MINOR REPAIR 6-41 6 Engine overheating W ARNING EWA10400 ● Do not remove the radiator cap when the e ngine and radiator are hot. Scalding hot fluid and steam may be blown out under pressur e, which could ca use serious injury. Be sure to wait until the engine has coole d. ● After removing the radiator cap retaining bo[...]

MOTORCYCLE CARE A ND ST ORAGE 7-1 7 EAU26060 Care While the open desig n of a mo torcycl e reveal s the a ttracti veness of the t ech- nology , it al so makes it m ore vul n era - ble. Rust and cor rosion can d evel op even if high-q uality compon ents are used. A rusty ex haust pipe m a y go un- notic ed on a car, howeve r, it detract s fro m the [...]

MOTORCYCLE CAR E AND STORAGE 7-2 7 After normal use Remov e dirt with warm wate r, a mild det ergent , and a so ft, cle an spon ge, and th en rinse th oroughly with cl ean wate r. Use a toot hbrush or bottle brush for h ard-t o-reac h areas. Stub born dirt and inse cts will com e off more e a sily if the ar ea is co vered wi th a wet c loth fo r a [...]

MOTORCYCLE CARE A ND ST ORAGE 7-3 7 ● Avoid using abrasive polishing compounds as they will wear away the pain t. NOTE: Consul t a Yama ha deal er for a dvice o n what pro ducts to use . EAU26230 Stor age Short-term Alway s store yo ur moto rcycl e in a cool , dry pl ace and, if necessar y, prot ect it agains t dust with a porou s cove r. CAUTION[...]

MOTORCYCLE CAR E AND STORAGE 7-4 7 W ARNING EWA10950 To prevent damage or injury from sparking, make sure to g round the spark plug electrodes while turning the engine over. 6. Lu bricate all c ontrol c ables an d the pivoting point s of al l lever s and pedals as we ll as of the side- stan d/cent ersta nd. 7. Check and, i f necessa ry, correct the[...]

SPECI FIC ATIO NS 8-1 8 Dimensions: Overa ll length: 2300 mm (90.6 in) Overa ll width: 795 mm (31.3 in ) Overa ll height: 1160 mm (45.7 in) Seat hei ght: 765 mm (30.1 in ) Wheel bas e: 1590 mm (62.6 in) Gro und clear ance: 145 mm (5.71 in ) Minimu m turni ng radius : 2900 mm (114. 2 in) Weight: With oil a nd fuel: 283.0 kg (624 lb) (U49) 284. 0 kg [...]

SPECIFICATIONS 8-2 8 Manuf acturer/m odel: DENSO/X24 EPR-U9 Spark p lug gap: 0.8 – 0.9 mm (0.031 – 0.035 in) Clut ch: Clutch type: Wet, multiple-disc Transmission: Primar y reducti on sy stem: Spur gea r Prim ary re duction r atio: 87/49 (1 .776) Second ary red uction sys tem: Shaft drive Second ary red uction rat io: 21/27 × 33/0 9 (2.852 ) T[...]

SPECI FIC ATIO NS 8-3 8 Front suspension: Type : Telescopic for k Spring /shock abso rber ty pe: Coil -ai r spri ng/oil damper Wheel trav el: 140.0 mm (5.51 in ) Rear suspension: Type : Swinga rm Spring /shock abso rber ty pe: Coil spr ing/oil da mper Wheel trav el: 100.0 mm (3.94 in ) Electrical system: Ignition system: Transistor ized coil igniti[...]

CONSUMER INFORMATI ON 9-1 9 EAU26351 Identification numbers Recor d the key iden tificatio n number, vehic le ide ntifica tion number and mo d- el labe l informa tion in the s p aces pro- vided bel ow for a ssistan ce when order ing spar e par ts from a Y amaha deal er or f or re feren ce in ca se the vehi - cle is stole n. KEY IDENTIFICATION NUMBE[...]

CONSUMER INFORMA T ION 9-2 9 EAU26530 Model label The mo del lab el is af fixed un der cowl- ing A. ( See pa ge 6-8 .) Rec ord the infor- mation on th is labe l in the sp ace prov ided. This informatio n will be need - ed when order ing spare parts from a Yamaha dealer. 1. Model label U5GK15E0.book P age 2 Tuesday, April 13, 2004 3:52 PM[...]

CONSUMER INFORMATI ON 9-3 9 EAU26550 Reporting safety defects If you be lieve that your vehicle has a def ect which c ould cau se a cra sh or coul d cause inj ury or dea th, you s hould im mediat ely infor m the Na tional Highw ay Tra ffi c Safety Ad ministrat ion (NH TSA) in ad dition to notify ing Ya maha Motor Corpo rati on, U.S .A. If NHTSA rec[...]

CONSUMER INFORMA T ION 9-4 9 EAU26560 Motorcycle noise regulation TAMPERIN G WITH NOISE C ONTROL SY STEM PROHI BITED: Federa l law pro hibits the followi ng acts or the causi ng there of: (1) Th e removal or renderi ng inop erativ e by any per son oth er than f or purpo ses of mai nten ance, rep air, or r eplacem ent o f any dev ice or el ement o f[...]

CONSUMER INFORMATI ON 9-5 9 EAU26631 Maintenance record Copies of work ord ers and/o r recei pts for parts purc hased and inst alled on your motor cycle will be re quired t o docu ment t hat maint enan ce has b een com pleted i n acco rdance wi th the em issio ns warra nty. Th e chart be low is p rinted only as a r eminde r that ma intenance w ork [...]

CONSUMER INFORMA T ION 9-6 9 36000 mi (55000 km) or 54 months 40000 mi (61000 km) or 60 months Maintenance interval Date of service Mile age Servicing dealer name and add ress Remarks U5GK15E0.book P age 6 Tuesday, April 13, 2004 3:52 PM[...]

CONSUMER INFORMATI ON 9-7 9 EAU26661 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5GK15E0.book P age 7 Tuesday, April 13, 2004 3:52 PM[...]

CONSUMER INFORMA T ION 9-8 9 U5GK15E0.book P age 8 Tuesday, April 13, 2004 3:52 PM[...]

CONSUMER INFORMATI ON 9-9 9 EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) K eep your Y amaha protected even after y our warranty expires with gen uine Y amaha Extended Ser vice (Y .E.S.). Y .E.S. is designed and administered by Y amaha Motor Corporation to provide maximum owner satisf action. Y ou get uninterrupted factory-backed co ver age for e xtra [...]

CONSUMER INFORMA T ION 9-10 9 We urge y ou to act now . Y ou ’ ll get the excellent benefits of TRIP cov erage right aw ay , and you ’ ll rest easy knowing you ’ ll hav e strong factory-backed protection e ven after your Y amaha Limited W arranty expires. A special note: If visiting your dealer isn ’ t con venient, contact Y amaha with your[...]

INDEX A Accessories and replacement parts ..... 6-22 Air filter element, cleaning ................... . 6-18 B Batter y ....... ........ ...... ........... ........ ....... ... 6-30 Brake and clutch fluid levels, checkin g ...... .......... ......... ...... ........... ... 6-25 Brake and clutch fluids, changing ......... 6-26 Brake and clutch lever[...]

INDEX Tires ..... ....... .... ...... ....... ........ ...... ........... 6 -20 Tool k it ...... .... ...... .... ....... ...... ........ ....... .... 6-1 Troubleshooting .................................... 6-39 Troubleshooting charts ...... ................... 6-40 Turn sig nal i ndic ator ligh t .... ...... .... ..... ..... 3-1 Turn signal light[...]

PRINTED IN JAPAN 2004.04-0.3 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 5GK-28199-15 LIT-11626-18-18 VMX12T(C) OWNER’S MANUAL[...]