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Yamaha 1998 VMAX Owner's Manual

1. 3 1 Recommended shift point 4 8 3 3 Engine break in 4 8 Brake clutch fluid leakage 3 4 Pal s e c Ep ate m 4 10 Throttle grip suse eae tiara tees 3 4 Engine 3 5 PERIODIC MAINTENANCE AND Final cU 3 5 MINOR REPAIR 5 1 COOL 3 6 Periodic maintenance 5 1 BIETER 3 7 dl 5 2 Cast wheels iei 3 10 Periodic maintenance emission Accessories or replacement parts 3 11 control SVS I iw 5 3 Chassis fasteners 3 11 General maintenance lubrication 5 5 Lights signals and switches 3 12 Spark plug inspection 5 9 Battery 3 12 Canister for California only 5 11 FUG sisse iens a uin dd 3 13 TOD COV 5 12 t 5 13 OPERATION AND IMPORTANT Finabgear veneta 5 17 RIDING POINTS 4 1 Cooling 5 19 Starting and warming up a cold Radiator TaN 5 25 ENJIN 4 2 5 25 Starting warm engine 4 6 Carburetor adjustment 5 27 4 6 Valve clearance adjustment 5 27 T
2. Frontfork Rear shock absorber Loading condition With accessory Damping With With accessory Air pressure Spring seat Solo rider equipment and adjuster passenger equipment passenger 40 60 kPa 0 4 0 6 kgf cm 5 7 8 5 psi 40 100 kPa 0 4 1 0 kgf cm 5 7 14 psi 40 100 kPa 0 4 1 0 kgf cm 5 7 14 psi Never attempt to turn the adjuster beyond the maximum or minimum setting 2 19 EAD50302 V Boost The V Boost is a vital part of the engine EUU39401 and requires very sophisticated adjust CUOY AY ment Adjustment should be left to a Yamaha dealer who has the professional knowledge and experience to do so The V Boost was set at the Yamaha facto ry after many tests If the settings are changed by someone without sufficient technical knowledge poor engine perfor mance and damage may result The V Boost operation can be heard when the main switch is turned on EUU39601 If the V Boost does not operate ask a Yamaha dealer to inspect it 2 20 EAD30101 Sidestand This model is equipped with an ignition circuit cut off system The motorcycle must not be ridden when the sidestand is down The sidestand is located on the left side of the frame Refer to page 4 2 for an explanation of this system EUU68901 4 WARNING This motorcycle must not be operated with the sidestand in the down position If the stand is not properly retracted it could c
3. ROUTINE PAGE _ Front and rear Check operation free play fluid level and fluid leakage 3 3 3 4 brakes Fill with DOT 4 brake fluid if necessary 5 28 5 33 Check operation fluid level and fluid leakage 3 4 5 33 Fill with DOT 4 or DOT 3 brake fluid if necessary Engine coolant e Check for coolant level and leakage 3 6 5 19 5 24 Fill with coolant if necessary Throttle Check for smooth operation 3 4 5 33 Adjust if necessary Check fluid level 7 Fill with distilled water necessary cl E 3 12 5 43 5 46 Check oil level Fill with oil as required 4 Final gear oil Check for leakage 3 5 5 17 5 19 Lights signals and switches Check for proper operation 3 1 ITEM ROUTINE PAGE 3 7 3 10 Wheels and tires Check tire pressure wear and damage 5 47 5 52 Check the tightness of all chassis nuts bolts and screws Chasse fasteners Tighten if necessary NOTE 21 eu e e cR LLL LL e aA Pre operation checks should be made each time the motorcycle is used Such an inspec tion can be accomplished in a very short time and the added safety it assures is more than worth the time involved 4 WARNING 1 The engine exhaust system will be very hot after the engine has been run Be careful not to touch them or to allow any clothing item to contact them during inspection or repair 2 lf any item in the PRE OPERATION CHECK is not working
4. YAMAHA 142motorcycle Dear Yamaha ATV Owner Please Review this IMPORTANT SAFETY CARD before operating your ATV If card is not attached call 1 800 344 6418 Dear New Yamaha ATV Owner CONGRATULATIONS ON THE PURCHASE OF YOUR NEW YAMAHA ATV You have purchased a quality Yamaha product that with proper use and care will provide hours of riding pleasure BEFORE YOU OPERATE YOUR NEW ATV Yamaha recommends these important points READ YOUR OWNER S MANUAL A CHILD UNDER 12 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE 70CC OR GREATER A CHILD UNDER 16 YEARS OLD SHOULD NOT OPERATE AN ATV WITH ENGINE SIZE GREATER THAN 90CC TAKE THE FREE HANDS ON TRAINING COURSE OFFERED BY YAMAHA ASK YOUR DEALER FOR DETAILS OR CALL 1 800 887 2887 If you have any questions about these points or if you purchased your ATV from an authorized Yamaha dealership and were not informed of the age recommendation for your ATV by the dealership please fill out the information below and mail this card to Yamaha today Name ATV Model Purchase Date READ CAREFULLY BUSINESS REPLY MAIL FIRST CLASS PERMIT NO 4 CYPRESS CA POSTAGE WILL BE PAID BY ADDRESSEE YAMAHA MOTOR CORPORATION U S A P O BOX 6555 CYPRESS CALIFORNIA 90630 9989 ATTN SALES ADMINISTRATION NO POSTAGE NECESSARY IF MAILED IN THE UNITED STATES EAA20201 INTRODUCTION Congratulations on your purchase of the Yamaha VMX12 VMX12C T
5. 6 1 6 2 SPECIFICATIONS uisi oiv cota epe 7 1 CONSUMER INFORMATION 8 1 Reporting safety defects 8 1 Motorcycle noise regulation 8 2 Maintenance record 8 3 Street and enduro motorcycle limited warranty 8 5 Yamaha extended service 8 7 EUU75602 SAFETY INFORMATION TWO WHEELED 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 HE OR SHE SHOULD 1 OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL AS PECTS 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 predom inating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the m
6. EAHO00000 PERIODIC MAINTENANCE AND MINOR REPAIR EAHO00101 Periodic inspection adjustment and lubri cation will keep your motorcycle in the saf est and most efficient condition possible Safety is an obligation of the motorcycle owner The most important points of mo torcycle inspection adjustment and lubri cation are explained in the following pages Maintenance replacement or repair of the emission control devices and systems may be performed by any repair establish ment or individual using any part which is certified if applicable EUU63200 WARNING If you are not familiar with motorcycle ser vice this work should be done by a Yamaha dealer 5 1 EAH00300 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 CON TROLS NOT ONLY FUNCTION TO EN SURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOL LOWING TABLES OF PERIODIC MAINTE NANCE 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 EAH10200 Tool kit 1 Tool kit 2 Fuel tank filler cover The service information included in this manual is intended to provide you the
7. EUU13601 NOTE 2 o e When installing the oil filter tighten it to the proper torque by using a torque wrench Tightening torque Oil filter 17 Nm 1 7 m kg 12 ft lb 5 16 h Fill the engine with sufficient oil to reach the specified level Install the oil filler cap and tighten it Recommended oil See page 3 5 Oil quantity Total amount 4 7 L 4 1 Imp qt 5 0 US qt Periodic oil change 3 5 L 3 1 Imp qt 3 7 US qt With oil filter replacement 3 8 L 3 3 Imp qt 4 0 US qt EUU32401 e Do not put in any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slip page e Be sure no foreign material enters the crankcase i Start the engine and warm it up for several minutes While warming up check for oil leakage If oil leakage is found stop the engine immediately and check for the cause j After the engine is started the oil level indicator light should go off if the oil is at the specified level EUU35101 If the indicator light flickers or remains on immediately stop the engine and consult with a Yamaha dealer 5 17 EAH40609 Final gear oil 1 Final gear oil 2 Correct oil level 3 Oil filler bolt EUU63400 WARNING Do not let foreign material enter the final gear case Be sure oil does not get on the tire or wheel 1 Oil level inspection a Place the motorcycle on a level place and place it on the centerstand The
8. NOTE s ees Brake fluid is also used for a hydraulic clutch DOT 4 or DOT 3 brake fluid can be used for the clutch system 5 Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boil ing point of the fluid and may result in vapor lock 6 Brake fluid may deteriorate painted surfaces or plastic parts Always clean up spilled fluid immediately EUU21400 1 Right side cover 1 Minimum level mark NOTE LOWER E o As the brake pads wear it is normal for the brake fluid level to gradually go down 3 Refill with the same type of brake flu id Mixing fluids may result in a harm ful chemical reaction and lead to poor brake or clutch performance 4 The diaphragm will lose its shape from the negative pressure if the brake fluid level goes down too far Be sure to put the diaphragm back in its origi nal shape before installing it into the master cylinder 5 32 EAH83501 Brake fluid replacement 1 Complete fluid replacement should be done only by trained Yamaha service personnel 2 Have a Yamaha dealer replace the fol lowing components during periodic maintenance or when they are dam aged or leaking a Replace all rubber seals every two years b Replace all hoses every four years 5 33 00702 Clutch lever free play adjustment This motorcycle has a hydraulic clutch There are no adjustments to perform but the clutch system must be insp
9. 1 When disassembling the master cylinder or caliper cylinder always replace the brake fluid Check the brake fluid level regularly and fill as required 2 Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years 3 Replace the brake hoses every four years or if cracked or damaged EAH20102 Spark plug inspection 1 Spark plug gap The spark plug is an important engine component and is easy to inspect The condition of the spark plug can indicate the condition of the engine Normally all spark plugs from the same engine should have the same color on the white insulator around the center elec trode The ideal color at this point is a me dium to light tan color for a motorcycle that is being ridden normally If one spark plug shows a distinctly different color there could be something wrong with the engine 5 9 Do not attempt to diagnose such problems yourself Instead take the motorcycle to a Yamaha dealer You should periodically remove and inspect the spark plugs be cause heat and deposits will cause any spark plug to slowly break down and erode If electrode erosion becomes exces sive or if carbon and other deposits are ex cessive you should replace the spark plug with the specified plug Specified spark plug DPRSEA 9 NGK or X24EPR U9 DENSO Before installing any spark plug measure the electrode gap with a wire thickness gauge Adjust the gap to sp
10. page 3 5 Clean with compressed air Replace if necessary Check hose for cracks or damage Replace if Cooling necessary system e Replace coolant every 24 months Adjust free Brake play system Replace pads if necessary Ethylene glycol antifreeze coolant 5 5 Final gear oil Control and meter cable Swingarm pivot bearing Brake clutch lever pivot shaft ROUTINE Check operation and fluid leakage See NOTE page 5 31 Correct if necessary Check oil level and leakage Replace every 24 000 km or 24 months Apply chain lube thoroughly Check bearing assembly for looseness Moderately repack every 24 000 km 15 200 mi Apply chain lube lightly SAE 80 API GL 4 hypoid gear oil Yamaha chain and cable lube or SAE 10W30 motor oil Medium weight wheel bearing grease Yamaha chain and cable lube or SAE 10W30 motor oil INITIAL ODOMETER READINGS 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km m 4 pes mi 8 is mi 12 ye mi 15 itty mi 19 ped mi 1 month 7 ond 13 moms 19 25 RTT 31 monis ODOMETER READINGS 13 000 km 19 000 km 25 000 km 31 000 km 8 200 mi 12 000 mi 15 800 mi 19 600 mi 1 000 km 600 mi or 1 month 7 000 km 4 400 mi or 7 months 13 months 19 months 25 months 31 months ITEM ROUTINE TYPE Yamah
11. Yamaha Service Marketing P O Box 6555 Cypress CA 90630 714 761 7631 8 8 Y YAMAHA EXTENDED SERVICE
12. a kerosene heater or near an open flame The motorcycle could catch fire 4 When transporting the motorcycle in another vehicle be sure it is kept upright If it 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 in your eyes see your doctor immediately If any gasoline spills on your skin or clothing immediately wash it off with soap and water and change your clothes 1 8 EAA40000 LOCATION OF THE IMPORTANT LABELS Please read the following labels carefully before operating this motorcycle DOO WARNING e BEFORE YOU OPERATE THIS VEHICLE READ THE OWNER S MANUAL AND ALL LABELS ALWAYS WEAR AN APPROVED MOTORCYCLE HELMET eye protection and protective clothing YAMAHA 3MX 2118K 00 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 YAMAHA 3JL 28177 00 TIRE INFORMATION Cold tire normal pressure should be set as follows Up to 90 kg 198 Ibs load FRONT 225 kPa 2 25 kgf cm 33 psi 225 kPa 2 25 kgf cm 33 psi REAR e 90 kg 198 Ibs maximum load FRONT REAR 225 kPa 2 25 kgf cm 33 psi 250 kPa 2 50 kgf cm2 36 psi 3LD 21668 10 California only EMISSION HOSE
13. down hard on the handlebars several times to check for proper fork opera tion Tighten the pinch bolt to the specified torque Tightening torque Pinch bolt 20 Nm 2 0 m kg 14 ft Ib 5 49 EAJ65002 Rear wheel removal 1 Axle nut EUU66202 WARNING It is advisable to have a Yamaha dealer service the wheel Securely support the motorcycle so there is no danger of it falling over 1 Place the motorcycle on the center stand Remove the axle nut as BLA GN RCAC C Od 1 Pinch bolt 3 Loosen the rear axle pinch bolt 4 Remove the caliper bolts and then the compression bar bolt by removing the cotter pin and nut EAJ30702 Rear wheel installation 5 While supporting the brake caliper 6 pull out the rear axle Move the wheel to the right to sepa rate it from the final gear case and re move the rear wheel EUUO5501 NOTE s Do not depress the brake pedal when the disc and caliper are separated 5 51 When installing the rear wheel reverse the removal procedure Pay attention to the following points 1 Apply a light coating of lithium base grease to final gear case splines and rear wheel hub splines Make sure the splines on the wheel hub fit into the final gear case Make sure there is enough gap be tween the brake pads before inserting the brake disc 4 Tighten the following parts to the specified torque
14. engine Normal Normal resistance Unusually light or heavy resistance Replace spark plugs Use electric starter if applicable 5 53 Have tank cap breather inspected for California only Check canister hoses for bend kink pinch clog etc Add fuel fuel OK No start Start engine Have engine inspected Engine turns fast battery is good Engine turns slowly electrical problem OK Go to compression check Go to ignition check Go to battery check Start OK Have engine No start inspected Have battery charged and system inspected EAKO00000 CLEANING AND STORAGE EAK02301 A CLEANING Frequent thorough cleaning of your mo torcycle will not only enhance its appear ance but will improve its general performance and extend the useful life of many components 1 Before cleaning the motorcycle a Block off the end of the exhaust pipes to prevent water entry a plastic bag and strong rubber band may be used b Make sure the spark plugs and all filler caps are properly installed 2 If the engine case is excessively greasy apply degreaser with a paint brush Do not apply degreaser to wheel axles 3 Rinse the dirt and degreaser off with a garden hose Use only enough pres sure to do the job 6 1 EUU34602 Excessive hose pressure may cause water seepage and deterioration of wheel bear ings front fork brakes tra
15. name as it is shown on your warranty identification your name and new mailing address Mail to YAMAHA MOTOR CORPORATION U S A WARRANTY DEPARTMENT P O Box 6555 Cypress California 90630 This will ensure that Yamaha Motor Corporation U S A has an up to date registration record in accordance with federal law YAMAHA EXTENDED SERVICE Y E S Keep your Yamaha protected even after your warranty n addition Travel and Recreation Interruption Protection expires with genuine Yamaha Extended Service Y E S TRIP is included at no extra cost TRIP gives you up to Y E S is designed and administered by Yamaha Motor 150 reimbursement per occurrence for any reasonable Corporation to provide maximum owner satisfaction You expenses you incur because your Yamaha needs get uninterrupted factory backed coverage for extra peace of mind Y E S is flexible You choose the plan that s right for you 12 months 24 months or 36 months beyond your warranty period Y E S is designed and administered by the same Yamaha people who handle your warranty and it shows in the comprehensive coverage benefits There are no mileage limitations Coverage isn t limited to moving parts or the drive train like many other plans And Y E S covers manufacturing defects just like the warranty See the sample contract at your Yamaha dealer to see how comforting uninterrupted factory backed protection can be You don t have to pay anything for c
16. properly have it inspected and repaired before operating the motorcycle 3 2 EAE13604 Brakes 1 Brake lever and brake pedal Check for correct free play in the front brake lever and correct rear brake ped al height Adjust if necessary Make sure the brakes are working properly by checking at low speed shortly after starting out See page 5 28 for de tails EUUG61900 WARNING soft spongy feeling the brake lever and or brake pedal indicates a failure in the brake system Do not operate the mo torcycle until the failure in the brake sys tem is corrected Ask a Yamaha dealer for immediate repairs soft spongy feeling could indicate a hazardous condition in the brake system 3 3 2 Brake fluid Check the brake fluid level Fil the master cylinder with brake fluid if nec essary See page 5 31 for details Recommended brake fluid DOT 4 3 Check the disc pads See page 5 30 for details EUUO2201 When this brake service is necessary con sult a Yamaha dealer EAE11601 Brake clutch fluid leakage Apply each brake and the clutch for a few minutes Check to see if any brake fluid leaks out from the hose joints master cyl inders or plunger case EUU37801 Brake fluid may deteriorate painted sur faces or plastic parts Never spill any fluid If spilled clean it up immediately EUU62500 WARNING If brake fluid leakage is found ask a Yamaha dealer for imme
17. to start release the start switch wait a few seconds then try again Each attempt should be as short as possi ble to preserve the battery Do not crank the engine more than 10 seconds on any one attempt EUU39802 The oil level indicator light and fuel indica tor light should come on when the start switch is pushed and should go off when the start switch is released If the oil level indicator light flickers or remains on im mediately stop the engine and check the engine oil level and for oil leakage If nec essary fill the engine with oil and check to see that the oil level indicator light goes off If not consult a Yamaha dealer 5 After starting the engine move the starter CHOKE to the warming up position EUUO2600 NOTE For maximum engine life always warm up the engine before starting off Never accel erate hard with a cold engine 6 After warming up the engine turn off the starter CHOKE completely 4 5 EUUO3101 NOTE e The engine is warm when it responds normally to the throttle with the start er turned off To avoid the possibility of excessive exhaust emissions never leave the starter circuit on longer than necessary The length of time the starter is needed depends upon the ambient temperature Warm ambient temperatures above 10 C bOF re quire about 7 seconds of starter use Cold ambient temperatures below 10 C 50 F require about 35 seconds with the starter turned on then a
18. 0 kPa 2 25 kgf cm 2 50 kgf cm 33 psi 36 psi Load is the total weight of cargo rider passenger and accessories 90kg 19816 load 225 kPa Maximum load EUU67701 A WARNING Proper loading of your motorcycle is im portant for several characteristics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Se curely pack your heaviest items close to the center of the motorcycle and distrib ute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVERLOAD YOUR MOTORCYCLE Make sure the total weight of the cargo rider passenger and accessories fairing saddlebags etc if ap proved for this model does not exceed the maximum load of the motorcycle Op eration of an overloaded motorcycle could cause tire damage an accident or even in jury 3 8 3 Wear indicator 1 Tread depth 2 Side wall 2 Tire inspection Always check the tires before operat ing 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 side wall is cracked contact a Yamaha dealer immediately and have the tire re placed FRONT 110 90 V18 G525AW REAR Dunop 150 90 V15 M C K525 150 90 V15 M C G526BW Minimum tire tread depth 1 0 mm 0 04 in front and rear EUU68001 4
19. AND EXCLUDED FROM THIS WARRANTY SOME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A P O Box 6555 Cypress California 90630 gt o gt gt WARRANTY QUESTIONS AND ANSWERS What costs are my responsibility during the warranty period The customer s responsibility includes all costs of normal maintenance services non warranty repairs accident and collision damage and oil oil filters air filters spark plugs and brake shoes or pads What are some examples of abnormal strain neglect or abuse These terms are general and overlap each other in areas Specific examples include Running the machine out of oil sustained high rpm full throttle use operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transporation and or tie down and so on If you have any specific questions on operation or maintenance please contact your dealer for advice Does the warranty cover inc
20. COVer 5 42 1 Battery positive lead 2 Starter motor lead EUU78201 WARNING Pass the battery positive lead and starter motor lead through the bracket hole as shown A short circuit could result from improper routing This could cause the en gine to stop running and lights to fail which could result in an accident When the motorcycle will not be used for a month or longer remove the battery fully charge it and store it in a cool dry place EUU50000 recharge the battery be fore storing Storing a discharged bat tery can cause permanent battery damage If the battery will be stored for longer than two months check the specific gravity of the fluid at least once a month and recharge the battery when it is too low Always make sure the connections are correct when reinstalling the bat tery Make sure the breather hose is properly connected and is not dam aged or obstructed 91502 Fuse replacement 1 Main fuse 2 Spare fuse There are two fuse boxes on this motorcy cle The main fuse box is located under the seat The sub fuse box is located under the top cover If any fuse is blown turn off the ignition switch and the switch of the circuit in question Install a new fuse of proper amperage Turn on the switches and see if the electrical device operates If the fuse immediately blows again consult a Yamaha dealer Specified fuse Main fuse Headlight fuse Signaling syst
21. EUU78000 4A WARNING Always use a new cotter pin Tightening torque Axle nut 150 Nm 15 0 m kg 108 ft lb Pinch bolt 16 Nm 1 6 m kg 11 ft lb Compression bar bolt 48 Nm 4 8 m kg 35 10 Caliper bolt 40 Nm 4 0 m kg 29 ft lb 5 52 EAJ50002 Troubleshooting Although Yamaha motorcycles receive a rigid inspection before shipment from the factory trouble may occur during opera tion Any problem in the fuel compression or ignition systems can cause poor starting and loss of power The troubleshooting chart describes a quick easy procedure for making checks If your motorcycle requires any repair bring it to a Yamaha dealer The skilled technicians at a Yamaha dealership have the tools experience and know how to properly service your motorcycle Use only genuine Yamaha parts on your mo torcycle Imitation parts may look like Yamaha parts but they are often inferior Consequently they have a shorter service life and can lead to expensive repair bills EAJ50800 Troubleshooting chart EUU66300 WARNING Never check the fuel system while smoking or in the vicinity of an open flame 1 Fuel Fuel check No start 2 Compression No start fuel OK Compression check 3 Ignition Ignition check Compression OK 4 Battery Battery check Fuel OK Compression OK Ignition OK Open tank cap to check internal pressure Turn over
22. ROUTING CARB FROM FUEL TANK CANISTER TO ATMOSPHERE YAMAHA MOTOR CO LTD A WARNING PASS LEAD WIRES THROUGH HOLE as shown A short circuit could result from improper routing This could cause the engine to stop running and lights to fail which could result in an accident 3JP 2415E 10 Right view uc NES 2 Wis e N lt OO a O 227 j n page 5 30 Tail brake light Rear turn signal light Fuel tank filler cover Top cover Main switch Right cover Rear brake pedal Right side cover 1 2 3 4 5 6 7 8 1 11 Left view iO 9 lt ii MEUS LO CN CN CN 5 2 ggg 12 D o o C uL X i D a C D _ 5 5 o foc E o 55 223 HE oa OYoodvc 0 m I o 1 12 Controls Instruments Y x 15 Clutch lever 16 Handlebar switches 17 Speedometer 18 Front brake lever 19 Throttle grip 20 Tachometer 21 Engine temperature gauge M WES ZR ONE digs Wa nV JA LJ za En IQQ J 2 amp 19 2 10 2 8 2 7 2 11 3 4 2 7 2 8 EAA60000 MOTORCYCLE IDENTIFICATION EAA61800 Identification numbers record Record the key identification number ve hicle identifica
23. TY INFORMATION 1 1 Engine temperature gauge 2 8 LOCATION OF THE IMPORTANT Handlebar switches 2 8 totu deae Pat burro fos 1 9 Cl tcli Ie Vel 2 10 DESCRIPTION 1 11 Shift Dedal 2 11 Left view eee 1 11 Front brake lever 2 11 RIONE VIEW aana 1 12 hear brake 2 11 Controls Instruments 1 13 Fuel tank inei opus us 2 12 MOTORCYCLE IDENTIFICATION 1 14 Starter CHOKE 2 13 Identification numbers record 1 14 Steering LOCK 2 14 Key identification number 1 14 Helmet holder 2 14 Vehicle identification number 1 15 Front fork adjustment 2 15 Model laDel cento pO ru eai Es 1 15 Rear shock absorber adjustment 2 17 Recommended combinations of the CONTROL FUNCTIONS 2 1 front fork and the rear shock E 2 1 absorber settings 2 19 Indicator usi duci etos vig 2 2 V BOOSL 2 20 Oil level indicator circuit check 2 4 oa du UR 2 21 Fuel indicator circuit check 2 6 Sidestand clutch switch operation Speedometer assaini 2 7 VE 2 22 TAG HONIG LO Do os 2 7 PRE OPERATION CHECKS
24. WARNING It is dangerous to ride with a worn out tire When a tire tread begins to show lines have a Yamaha dealer replace the tire immediately Brakes tires and related wheel parts replacement should also be left to a Yamaha dealer 3 9 EUU77602 WARNING This motorcycle is fitted with super high speed running tires The following points must be observed in order for you to make fully effective use of these tires 1 Never fail to use the specified tires in tire replacement Other tires may have a danger of bursting at super high speeds New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approxi mately 100 km 60 mi should be trav eled at normal speed before any high speed riding is done 3 Before any high speed runs the tires should be warmed up sufficiently Always inflate to the correct tire pres sure according to the operating condi tions EAE97600 Cast wheels To ensure maximum performance long service and safe operation note the fol lowing 1 Always inspect the wheels before a ride Check for cracks bends or warpage of the wheels If any abnor mal condition exists in a wheel con sult a Yamaha dealer Do not attempt even small repairs to the wheel If a wheel is deformed or cracked it must be replaced Tires and wheels should be balanced whenever either one is changed or re placed Failure to have a wheel b
25. a chain Brake pedal Lubricate and shift Apply chain and cable lube or pedal shaft lube lightly Check SAE 10W30 motor oil operation Yamaha chain Center side and and cable lube or stand pivots lubricate SAE 10W30 Apply chain motor oil lube lightly operation and leakage bearing assembly for looseness Moderately repack every 24 000 km 15 200 mi Medium weight wheel bearing Steering bearings Wheel bearings bearings for smooth rotation specific gravity and breather pipe for proper operation ODOMETER READINGS 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km ITEM ROUTINE 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or Check and Sidestand clean or switch replace if necessary Items marked with an asterisk require special tools data and technical skills for servicing Take the motorcycle to a Yamaha Dealer or refer to the Service Manual when servicing these items NOTE e The air filter needs more frequent service if you are riding in unusually wet or dusty ar eas e For odometer readings or time periods higher than 31 000 km 19 600 mi or 31 months repeat the same maintenance as listed in the table from the 7 000 km 4 400 mi or 7 months every 6 000 km 3 800 mi or 6 month interval e Brake fluid replacement
26. a s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs will be warranted for the balance of the pro duct s warranty period All parts replaced under war ranty become property of Yamaha Motor Corporation U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by a Competition or racing use b Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Lack of proper maintenance Accident or collision damage Modification to original parts Damage due to improper transportation o 7920 SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance THE CUSTOMER S RESPONSIBILITY under this war ranty shall be to 1 Operate and maintain the motorcycle as specified in the appropriate Owner s Manual and 2 Give notice to an authorized Yamaha motorcycle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspection and repairs at such dealer s place of business WARRANTY TRANSFER To transfer the warranty from the original purchaser to any subsequent pur chaser it is imperative that the machine be inspected and registered for warranty by an authorized Yamaha motorcycle dealer In order for this warranty to remain in effect t
27. adia tor 5 25 1 Air filter case cover The air filter should be cleaned at the spec ified intervals It should be cleaned more frequently if you are riding in unusually wet or dusty areas 1 Remove the top cover 2 Remove the air filter case fitting screws and the filter case cover 3 Pull out the air filter 4 Tap the air filter lightly to remove most of the dust and dirt Blow out the remaining dirt with compressed air as shown If the air filter is damaged re place it 5 Reassemble by reversing the removal procedure 5 26 EUU42403 e Make sure the air filter is properly seated in the air filter case e The engine should never be run with out the air filter installed Excessive piston and or cylinder wear may re sult EAH93002 Carburetor adjustment The carburetors are important parts of the engine and emission control system Ad justing should be left to a Yamaha dealer with the professional knowledge special ized data and equipment to do so properly 5 27 EAH90801 Valve clearance adjustment The correct valve clearance changes with use resulting in improper fuel air supply or engine noise To prevent this the valve clearance must be adjusted regularly This adjustment however should be left to a professional Yamaha service technician EAH80104 Front brake lever free play adjustment 1 Locknut 2 Adjusting bolt 3 Free play The free play at the front brake lever should
28. al anced can result in poor performance adverse handling characteristics and shortened tire life Ride at moderate speeds after chang ing a tire since the tire surface must first be broken in for it to develop its optimal characteristics Tightening torque 4 After repairing or replacing a tire tighten the valve stem locknut to the specified torque Valve stem locknut 1 5 Nm 0 15 m kg 1 1 ft Ib EAE93900 Accessories or replacement parts EUU69700 A 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 de signed specifically for it and they must be securely mounted to maintain the inher ent stability of the original design Genu ine Yamaha Parts and Accessories are designed and tested to be compatible with your motorcycle Please consider Genuine Yamaha Parts and Accessories before making an accessory purchase Use of non Yamaha approved parts or acces sories may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of parts or accessories manufactured by other companies Yamaha cannot be held liable for any con sequences caused by the use of items which have not been approved by Yamaha 3 11 EAE85101 Chassis fasteners Always check the tightness of all chassis nuts bolts and screws before a ride Take the motorcycle to a Yamaha dealer or
29. al is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake EACO0401 Fuel tank cap 1 Lever TO OPEN 1 Push the levers left and right of the fuel tank filler cover and slide the cov er forward to open it Insert the key and turn it clockwise 1 4 turn The lock will be released and the cap can be opened 2 12 1 Open TO CLOSE 1 Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original position EUUO1200 NOTE e x This tank cap cannot be closed unless the key is in the lock The key cannot be re moved if the cap is not locked properly 2 Slide the fuel tank filler cover rearward and push it down EUU61100 WARNING Be sure the cap is properly installed and locked in place before riding the motorcy cle 2 13 EAC20502 Starter CHOKE 1 Starter CHOKE Starting a cold engine requires a richer air fuel mixture A separate starter circuit sup plies this mixture Move in direction 3 to turn on the starter Move in direction to turn off the starter EAC30201 Steering lock To lock the steering turn the handlebars all the way to the right Open the steering lock cover turn the key 1 8 counterclock wise then push the key in and turn it 1 8 turn clockwise After checking to see that the steering is locked remove the key from the lock and close the cover T
30. and both feet on the op erator footrests during operation to maintain control of the motorcycle b The passenger should always hold on to the operator or the seat strap or grab bar if the motorcycle is so 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 passen ger footrests Never ride under the influence of alcohol or drugs This motorcycle is designed for on road use only It is not suitable for off road use 1 3 PROTECTIVE APPAREL The majority of fatalities from motorcycle accidents are the result of head injuries The use of a safety helmet is the single most critical factor in the prevention or reduction of head injuries 1 2 3 6 Always wear an approved helmet Wear a face shield or goggles Wind on your unprotected eyes could contribute to an impairment of vision which could delay seeing a hazard The use of heavy boots jacket trousers gloves etc is effective in preventing or re ducing abrasions or lacerations Never wear loose fitting clothing It could catch on the control levers footrests or wheels and cause injury or accident 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 A passenger should also observe the above precautions MODIFICATION Modifi
31. assed by or passing large vehicles c Certain accessories can displace the operator from his or her normal riding posi tion This improper position limits the freedom of movement of the operator and may limit control ability Therefore such accessories are not recommended 2 Caution must be used if adding electrical accessories these 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 off the engine when refueling b Take care not to spill any gasoline on the engine or exhaust system when refuel ing 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 ex haust 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 off the engine before leaving the motorcycle unattended and remove the ignition key When parking the motorcycle note the following a The engine and exhaust system may be hot 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 the motorcycle may fall over c Do not park the motorcycle near a flammable source e g
32. be 2 5 mm 0 08 0 20 in 1 Loosen the locknut 2 Turn the adjusting bolt in direction 8 to increase free play or in direction b to decrease free play 3 After adjusting tighten the locknut EUU81500 A WARNING Check the brake lever free play Be sure the brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system This air must be removed by bleeding the brake sys tem before the motorcycle is operat ed Air in the system will cause greatly diminished braking capability and can result in loss of control and an accident Have a Yamaha dealer in spect and bleed the system if neces sary EAH80402 Rear brake pedal height adjustment 1 Pedal height The top of the brake pedal should be posi tioned 10 30 mm 0 4 1 2 in below the top of the footrest If not ask a Yamaha dealer to adjust it 5 29 EUU79300 WARNING soft spongy feeling the brake pedal can indicate the presence of air in the brake system This air must be removed by bleeding the brake system before the motorcycle is operated Air in the system will cause greatly diminished braking ca pability and can result in loss of control and an accident Have a Yamaha dealer in spect and bleed the system if necessary EAH83302 Brake light switch adjustment IO Nar di d Q J Jh 1 Main body ga 2 Adjusting nut The rear brak
33. ble then leaded regular gasoline can be used 3 14 Gasohol There are two types of gasohol gasohol containing ethanol and that containing methanol Gasohol containing ethanol can be used if ethanol content does not exceed 10 Gasohol containing methanol is not recommended by Yamaha because it can cause fuel system damage or vehicle per formance problems EAF00000 OPERATION AND IMPORTANT RIDING POINTS EUU31100 EUU67201 WARNING 1 careful where you store personal 1 Before riding this motorcycle become items on the motorcycle Avoid block thoroughly familiar with all operating ing the air cleaner intake or perfor controls and their functions Consult a Yamaha dealer regarding any control or function that you do not thorough understand mance will suffer Be careful not to put anything near the battery and its terminals Electri cal failure and acid corrosion may re 2 Never start your engine or let it run sult for any length of time in a closed area The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time Always op erate your motorcycle in an area with adequate ventilation 3 Before starting out always be sure the sidestand is up Failure to retract the sidestand completely can result in a serious accident when you try to turn a corner 4 1 EAF13007 Starting and warming up a cold engine EUUO2802 NOTE This motorcycl
34. bout 2 5 minutes with the starter in the half way position For maximum engine life always warm up the engine before starting off Never accelerate hard with a cold engine EAF10802 Starting a warm engine The starter CHOKE is not required when the engine is warm EUUS31401 See the Engine break in section prior to operating the motorcycle for the first time 4 6 EAF20003 Shifting The transmission lets you control the amount of power you have available at a given speed for starting accelerating climbing hills etc The use of the shift ped al is shown in the illustration Page 2 11 To shift into neutral depress the shift ped al repeatedly until it reaches the end of its travel then raise the pedal slightly EUUS1501 1 Do not coast for long periods with the engine off and do not tow the motor cycle a long distance Even with gears in neutral the transmission is only properly lubricated when the engine is running Inadequate lubrication may damage the transmission 2 Always use the clutch when changing gears The engine transmission and driveline are not designed to with stand the shock of forced shifting and can be damaged by shifting without using the clutch EAF20101 To start out and accelerate 1 2 Pull the clutch lever to disengage the clutch Shift into first gear The neutral indica tor light should go out Open the throttle gradually and at the same time rel
35. cations made to the motorcycle not approved by Yamaha or the removal of orig inal equipment may render your motorcycle unsafe for use and may cause severe per sonal injury Modifications may also make your motorcycle illegal to use 1 4 LOADING AND ACCESSORIES Adding accessories or cargo to your motorcycle can adversely affect stability and han dling if the weight distribution of the machine is changed To avoid the possibility of an accident extreme caution should be used if adding cargo or accessories to your motor cycle Use extra care if riding a motorcycle which has added cargo or accessories Here are some general guidelines to follow if loading cargo or adding accessories to your mo torcycle The total weight of the operator passenger accessories and cargo must not exceed the maximum load limit of VMX12 476 Ibs 216 kg VMX12C 474 Ibs 215 kg When loading within these weight limits keep the following in mind 1 Cargo and accessory weight should be kept as low and close to the motorcycle as possible Be sure to distribute the weight as evenly as possible on both sides of the machine to minimize imbalance or instability 2 Shifting weights can create a sudden imbalance Make sure that accessories and car go are securely attached to the motorcycle before riding Recheck accessory mounts and cargo restraints frequently 3 Never attach any large or heavy items to the handlebars front forks or front fender These
36. cle dealer for the warranty coverage to remain effective CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha motorcycle dealer within the continental United States Be sure to bring your warranty registration identification or other valid proof of the original date of purchase If a question or problem arises regarding warranty first contact the owner of the dealership Since all warranty matters are handled at the dealer level this person is in the best position to help you If you are still not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any important information such as names addresses model engine serial number dates and receipts CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to maintain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registrations sent to Yamaha Motor Corporation U S A by the selling dealer at the time of your purchase If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name engine serial number dealer number or dealer s
37. diate repairs Such leakage could indicate a hazardous condition 3 4 EAE30104 Throttle grip a Free play Turn the throttle grip to see if it operates properly Make sure the grip returns by spring force when released There should be a free play of 3 5mm 0 12 0 20 in at the throttle grip If the free play is incorrect ask a Yamaha dealer to make this adjust ment EAE40003 Engine oil Make sure the engine oil is at the specified level Fill with oil as necessary See page 5 13 for details Recommended oil 30 F 40 F 50 F 60 F YAMALUBE 4 20W40 or SAE 20W40 type SE motor oil YAMALUBE 4 10W30 or 0 5 C 10 15 C SAE 10W30 type SE motor oil Recommended engine oil classification API Service SE SF type or equivalent e g SF SE SF SE CC SF SE SD etc Oil quantity Total amount 4 7 L 4 1 Imp qt 5 0 US qt Periodic oil change 3 5 L 3 1 Imp qt 3 7 US qt With oil filter replacement 3 8 L 3 3 Imp qt 4 0 US at 3 5 40301 Final gear oil Make sure the final gear oil is at the speci fied level Fill with oil as necessary See page 5 17 for details Recommended SAE 80 API GL 4 Hypoid gear oil If desired an SAE 80W90 hypoid gear oil may be used for all conditions EUUO2300 _ GL 4 is a quality and additive rating GL 5b or GL 6 rated hypoid gear oils may also be used EAE60005 Coolant 1 Coolant reservoi
38. e is equipped with an igni tion circuit cut off system 1 The engine can be started only under the following conditions a The transmission 1 in neutral b The sidestand is up the transmission is in gear and the clutch is disengaged 2 The motorcycle must not be ridden when the sidestand is down EUUG9200 44 WARNING Before going through the following steps check the function of the sidestand switch and clutch switch Refer to page 2 22 4 2 TURN THE MAIN SWITCH TO ON AND THE ENGINE STOP SWITCH TO RUN IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND SIDESTAND IS DOWN SIDESTAND IS UP PUSH START SWITCH PULL IN CLUTCH LEVER AND PUSH START ENGINE WILL START SWITCH ENGINE WILL START RETRACT SIDESTAND AND PUT TRANSMISSION IN GEAR MOTORCYCLE CAN BE RIDDEN MOTORCYCLE CAN BE RIDDEN 1 Turn the main switch to ON and the engine stop switch to RUN EUU39903 If the fuel indicator light comes on check the fuel level If necessary fill the tank with fuel 2 Shift the transmission into neutral EUU03001 When the transmission is in neutral the neutral indicator light should be on If the light does not come on ask a Yamaha dealer to inspect it 3 Turn on the starter CHOKE and completely close the throttle grip 4 Start the engine by pushing the start Switch 4 4 EUUO2501 NOTE 2 If the engine fails
39. e light switch is activated by the brake pedal and is properly adjusted when the brake light comes on just before braking takes effect To adjust the rear brake light switch hold the switch body so it does not rotate while turning the adjust ing nut Turn the adjusting nut in direction 8 to make the brake light come on earlier Turn the adjusting nut in direction to make the brake light come on later 5 30 EAH83601 Checking the front and rear brake pads 1 Wear indicator A wear indicator is provided on each brake This indicator allows checking of brake pad wear without disassembling the brake Apply the brake and inspect the wear indicator If the indicator is ALMOST in contact with the disc plate ask a Yamaha dealer to replace the pads EAH807A3 Inspecting the brake fluid level Front brake 1 Minimum level mark LOWER Insufficient brake fluid may let air enter the brake or clutch system possibly causing them to become ineffective Before riding check that the brake fluid is above the min imum level and replenish when necessary Observe these precautions 1 When checking the fluid level make sure the top of the master cylinder is level by turning the handlebars 5 31 1 Minimum level mark LOWER 2 Use only the designated quality brake fluid Otherwise the rubber seals may deteriorate causing leakage and poor brake or clutch performance Recommended brake fluid DOT 4 EUU 19601
40. e or during sudden acceleration or deceleration but this is not abnormal 2 3 EAB30106 Oil level indicator circuit check Turn the main switch to ON and the engine stop switch to RUN Oil level indicator light comes on Oil level indicator light does not come on Putthe transmission in neutral or apply the clutch lever then Check engine oil level push the start switch Oil level indicator light Oil level indicator light Oil level Oil level comes on does not come on is OK is low Engine oil level and Ask a Yamaha dealer to Supply electrical circuit are OK inspect electrical circuit engine oil Go ahead with riding t TIITTTIIT 0 EO0E0SE0S0SES0ESnn0nPPPPPPPPPPPIPPDPEEPEERERIEIEPIEEPEEIEIETEIPRIIIEREIIREIEEPEPERIIDELIEEEIIIPEZIIEIIEITEEEIEEELIILLILLELEEEASEEELLLLLLLLEELLLLELELL ELLE EAB 13501 Fuel indicator light FUEL When the fuel level drops below approxi mately 3 L 0 7 Imp gal 0 8 US gal this light will come on When this light comes on move the fuel switch to RES Then fill the tank at the first opportunity 2 5 EAB30705 Fuel indicator circuit check Turn the main switch to ON and the engine stop switch to RUN Fuel indicator light does Fuel indicator light not come on comes on Put the transmission in neutral Check the fuel level or apply the clutch le
41. ease the clutch lever slowly At the recommended shift point in the table below close the throttle and at the same time quickly pull in the clutch lever Shift into second gear Be careful not to shift into neutral Open the throttle part way and gradu ally release the clutch lever Follow the same procedure when shifting to the next higher gear Al ways shift gears at the recommended shift points 4 7 EAF20302 To decelerate 1 3 Apply both the front and the rear brakes at the same time to slow the motorcycle When the motorcycle reaches 20 km h 12 5 mi h shift into first gear Any time the engine is about to stall or runs very roughly pull in the clutch and use the brakes to stop When the motorcycle is almost com pletely stopped shift into neutral The neutral indicator light should come on EAF20500 EAF30000 Recommended shift point Engine break in There is never more important period in Acceleration Deceleration shift point shift point the life of your motorcycle than the period km h mi h km h mi h between zero and 1 000 km 600 mi For Ist 2nd 16 10 0 20 12 5 this reason we ask that you carefully read 2nd 3rd 24 15 0 20 12 5 the following material Because the engine 3rd 4th 32 20 0 20 12 5 SED 4th 5th 40 25 0 20 12 5 TOUS pa ane nae sive load on it for the first 1 000 km 600 mi The various parts in the engine wear a
42. ecification Spark plug gap 0 8 0 9 mm 0 031 0 035 in When installing the spark plug always clean the gasket surface and use a new gasket Wipe off any grime from the threads and tighten the spark plug to the specified torque Tightening torque Spark plug 18 Nm 1 8 m kg 13 ft lb EUU03802 NOTE If a torque wrench is not available when you are installing a spark plug a good esti mate of the correct torque is 1 4 to 1 2 turn past finger tight Have the spark plug tight ened to the specified torque as soon as possible 5 10 EAH90401 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Before using this motor cycle be sure to 1 Check each hose connection 2 Check each hose and canister for cracks or damage Replace if dam aged 3 Make sure the vent hose is not blocked Clean it if necessary 5 11 To carburetor From fuel tank ep Canister To atmosphere EAC70602 Top cover 1 Unlock To remove the top cover insert the key in To reinstall the top cover fit the top cover the lock and turn it clockwise Then pull up brackets onto the lobes of the frame Then ward push down on the rear of the top cover 5 12 48504 Engine oil 1 Level window 3 Minimum level mark 1 Oil level inspection a Place the motorcycle on the center stand Warm up the engine for several minut
43. ected peri odically for proper fluid level and leakage If the control lever free play becomes ex cessive and the motorcycle creeps or stalls when shifted into gear or if the clutch slips causing acceleration to lag behind engine speed there is probably air in the clutch system and it must be bled out Ask a Yamaha dealer to do this service EAI10101 Cable inspection and lubrication EUU64601 A WARNING Damage to the outer housing of cables may allow internal rusting and cause in terference with cable movement Replace damaged cables as soon as possible to prevent unsafe conditions Lubricate the inner cable and the cable end If it does not operate smoothly ask a Yamaha dealer to replace them Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil 5 34 EAI10201 Throttle cable and grip lubrication The throttle twist grip assembly should be greased at the time that the cable is lubri cated since the grip must be removed to get at the end of the throttle cable After re moving the screws hold the end of the ca ble up in the air and put in several drops of lubricant With the throttle grip disassem bled coat the metal surface of the grip as sembly with a suitable all purpose grease EAI30202 Brake and shift pedal lubrication Lubricate the pivoting parts EAI30301 Brake and clutch lever lubrication Lubricate the pivoting parts Recommended lubricant Recommended lubrica
44. em fuse Fan fuse Ignition fuse 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Fan fuse 5 Spare fuse EUU34400 Do not use fuses of higher amperage rat ing than those recommended Substitu tion of a fuse of improper rating can cause extensive electrical system damage and possibly a fire 5 44 EAI88304 Headlight bulb replacement This motorcycle is equipped with a quartz bulb headlight If the headlight bulb burns out replace the bulb as follows 1 Remove the screws holding the light unit assembly 2 Remove the connectors the light unit assembly and then the bulb holder COVer E ZY 1 Bulb holder 3 Turnthe bulb holder counterclockwise to remove it and remove the defective bulb 5 45 1 Don t touch EUU66002 4 WARNING Keep flammable products and your hands away from a bulb while it is on as it is hot Do not touch a bulb until it cools down 4 Put a new bulb into position and se cure it in place with the bulb holder 5 46 EUU34101 Avoid enm the glass nan of a bulb Keep it free from oil otherwise the trans parency of the glass life of the bulb and luminous flux will be adversely affected If oil gets on a bulb thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 5 Install the bulb holder cover connec tors and the light unit assembly If the headlight beam adjustment is neces sary as
45. engine should be cool at ambient tem perature b Remove the oil filler bolt and check the oil level The oil level should be at the brim of the hole Fill with oil as neces sary 1 Drain plug 2 Gear oil replacement a Place an oil pan under the final gear case b Remove the oil filler bolt and the drain plug to drain the oil c Reinstall and tighten the drain plug to the specified torque Tightening torque Drain plug 23 Nm 2 3 m kg 17 ft lb 5 18 d Fill the gear case to the brim of the hole with the recommended oil Final gear oil Recommended oil See page 3 5 Oil quantity 0 2 L 0 18 Imp qt 0 21 US qt e Reinstall and tighten the oil filler bolt to the specified torque Tightening torque Oil filler bolt 23 Nm 2 3 m kg 17 ft lb f After replacement of the final gear oil be sure to check for oil leaks 5 19 EAH50406 Cooling system 1 If your motorcycle overheats EUU70501 A 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 inju ry Open the radiator cap as follows Wait until the engine has cooled Place a thick rag like a towel over the radiator cap and slowly rotate the cap counterclock wise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counte
46. er Displacement 1 198 cm 73 1 cu in Bore x stroke 76 x 66 mm 3 0 x 2 6 in Compression ratio 10 5 1 Starting system Electric starter Lubrication system Wet sump 7 1 Oil type or grade Engine oil Final gear oil Cil capacity Engine oil Periodic oil change With oil filter replacement Total amount Final gear oil Total amount See page 3 5 See page 3 5 3 5 L 3 1 Imp qt 3 7 US qt 3 8 L 3 3 Imp at 4 0 US qt 4 7 L 4 1 Imp qt 5 0 US qt 0 2 L 0 18 Imp at 0 21 US qt Radiator capacity including all routes 3 05 L 2 68 Imp qt 3 22 US qt Dry type element Air filter Fuel Type Tank capacity Reserve amount Carburetor Type quantity Manufacturer 7 2 UNLEADED FUEL 15 L 3 3 Imp gal 4 0 US gal 3 L 0 7 Imp gal 0 8 US gal BDS35 4 MIKUNI Spark plug Type Manufacturer Spark plug gap Clutch type Transmission Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio Chassis Frame type Caster angle Trail DPR8EA 9 X24EPR U9 NGK DENSO 0 8 0 9 mm 0 031 0 035 in Wet multiple disc 7 3 Spur gear 87 49 1 775 Shaft drive 21 27 x 33 9 2 851 Constant mesh 5 speed Left foot operation 43 17 2 529 39 22 1 772 31 23 1 347 28 26 1 076 26 28 0 928 Double cradle 29 119 mm 4 69 in Tubeless 110 90 V18 150 90 V15 M C type Dual disc brake opera
47. er for 15 minutes and 5 39 get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield your eyes when working near batteries KEEP OUT OF REACH OF CHILDREN otorage 1 The level should be between the max imum and minimum marks Use only distilled water if refilling is necessary To fill the battery with fluid a Open the fuel tank filler cover and re move the seat 1 Maximum level mark 2 Minimum level mark Replenishing the battery fluid A poorly maintained battery will corrode and discharge quickly The battery fluid should be checked at least once a month The level should be between the minimum and maximum marks Use only distilled water if refilling is necessary EUU33800 Normal tap water contains minerals which are harmful to a battery therefore refill only with distilled water 5 40 b Disconnect the leads as shown and re move the ignition coil holding bolts 5 41 a We BAS LUNA ic SY 4 SY Rat 2 Ignition coil assembly 4 Starter motor lead 1 Ignition coil holding bolt x 2 3 Battery positive lead c Position the ignition coil so that it s not in the way and fill battery with flu id Reinstall the ignition coil assembly and reconnect the leads Reinstall the seat and fuel tank filler
48. es EUUO3901 NOTE Be sure the motorcycle is positioned straight up when checking the oil level A slight tilt toward the side can result in false readings 2 Maximum level mark 5 13 b With the engine stopped check the oil level through the level window locat ed at the lower part of the right side crankcase cover EUU04000 NOTE 2 8 Wait a few minutes until the oil level set tles before checking c The oil level should be between the maximum and minimum marks If the level is low fill the engine with suffi cient oil to reach the specified level 1 B io EN 2 Engine oil and oil filter cartridge re c Remove the drain plug and drain the 1 Engine oil drain plug placement oil a Warm up the engine for several min utes b Stop the engine Place an oil pan un der the engine and remove the filler cap 5 14 1 Oil filter 2 Oil filter wrench d Remove the oil filter by using an oil fil ter wrench EUU13001 An oil filter wrench is available at nearby Yamaha dealer e Reinstall the drain plug and tighten it to the specified torque Tightening torque Drain plug 43 Nm 4 3 m kg 31 ft Ib 1 O ring f Apply a light coat of engine oil to the O ring of the new oil filter EUUO4101 NOTE Make sure the O ring is seated properly 1 Torque wrench g Install the new oil filter and tighten it to the specified torque with an oil filter wrench
49. ha dealer Standard air pressure 40 kPa 0 4 kgf cm 5 7 psi Maximum air pressure 100 kPa 1 0 kgf cm 14 psi Minimum air pressure 40 kPa 0 4 kgf cm 5 7 psi EUU33400 Never exceed the maximum pressure or oil seal damage may occur EUU66502 A WARNING There must not be more than 10 kPa 0 1 kgf cm 1 4 psi difference in air pressure between the left and right fork legs 4 Install the valve caps securely EAI50802 Rear shock absorber adjustment 1 Rear shock absorber a Increase b Decrease This shock absorber is equipped with a 1 Adjust spring preload as follows spring preload and damping force adjust Turn adjuster in direction 8 to in er crease spring preload and in direction 6 to decrease spring preload Standard position 1 1 Minimum soft 5 Maximum hard 2 17 EUU65200 WARNING Always adjust each shock absorber to the same setting Uneven adjustment can cause poor handling and loss of stability 1 Damping adjuster a Increase b Decrease 2 Adjust damping force as follows Turn adjuster in direction to in crease damping force and in direction b to decrease damping force Standard position 1 1 Minimum soft 4 Maximum hard 2 18 EAI53103 Recommended combinations of the front fork and the rear shock absorber settings Use this table as a guide for specific settings according to motorcycle load conditions
50. his inspection and registration must take place within ten 10 days after transfer An inspec tion and registration fee will be charged for this service EMISSIONS CONTROL SYSTEM WARRANTY Yamaha Motor Corporation U S A also warrants to the ultimate purchaser and each subsequent purchaser of each Yamaha motorcycle covered by this warranty with a displacement of 5Occ or greater that the vehi cie is designed built and equipped so as to conform at the time of sale with all U S emissions standards applicable at the time of manufacture and that it is free from defects in materials and workmanship which would cause it not to meet these standards within the periods listed immediately below Failure other than those resulting from defects in material or workman ship which arise solely as a result of owner abuse and or lack of proper maintenance are not covered by this warranty ENGINE DISPLACEMENT 5Occ to 169cc PERIOD 12 000 km 7 465 miles or five years whichever occurs first 170cc to 279cc 18 000 km 11 185 miles or five years whichever occurs first 30 000 km 18 641 miles or five years whichever occurs first 280cc or over YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A
51. his model is the re sult of Yamaha s vast experience in the production of fine sporting touring and paceset ting 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 main tenance of this motorcycle If you have any questions about 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 stan dards without reducing the motorcycle s performance or economy of operation To main tain these high standards it is important that you and your dealer pay close attention to the recommended maintenance schedules and operating instructions contained within this manual EAA10700 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following nota tions AN The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator a bystander or a person inspect ing or repairing the motorcycle A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle NOTE A NOTE provides key information t
52. idental costs such as towing or transportation due to a failure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Manual instead of having the dealer do them Yes if you are a qualified mechanic and follow the procedures specified in the Owner s and Service Manual We do recommend however that items requiring special tools or equipment be done by a Yamaha motorcycle dealer Will the warranty be void or cancelled if do not operate or maintain my new motorcycle exactly as specified in the Owner s Manual No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Manual that failure may not be covered under warranty What responsibility does my dealer have under this warranty Each Yamaha motorcycle dealer is expected to 1 Completely set up every new machine before sale 2 Explain the operation maintenance and warranty requirements to your satisfa tion at the time of sale and upon your request at any later date In addition each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work 15 the warranty transferable to second owners Yes The remainder of the existing warranty can be transferred upon request The unit has to be inspected and re registered by an authorized Yamaha motorcy
53. ine EAB60703 Start switch START The starter motor cranks the engine when pushing the start switch EUU30700 See starting instructions prior to starting the engine EAB61404 Fuel reserve switch FUEL This switch should usually be kept on while riding If the fuel indicator light comes on while riding move the switch to RES and refuel at the first opportunity Then move the switch to ON EUU 12901 NOTE When the switch is turned to reserve RES about 3 L 0 7 Imp gal 0 8 US gal remain in the fuel tank 2 10 EAB70003 Clutch lever The clutch lever is located on the left han dlebar and the ignition circuit cut off sys tem is incorporated in the clutch lever holder Pull the clutch lever to the handle bar to disengage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth clutch operation Refer to the engine starting procedures for a de scription of the ignition circuit cut off sys tem EAB80001 Shift pedal 1 Shift pedal N Neutral This motorcycle is equipped with a con stant mesh 5 speed transmission The shift pedal is located on the left side of the engine and is used in combination with the clutch when shifting 2 11 EAB90001 Front brake lever The front brake lever is located on the right handlebar Pull it toward the handlebar to apply the front brake EAB90101 Rear brake pedal The rear brake ped
54. items including such cargo as sleeping bags duffle bags or tents can create unstable handling or slow steering response ACCESSORIES Genuine Yamaha accessories have been specifically designed for use on this motorcy cle Since Yamaha cannot test all other accessories which may be available you must personally be responsible for the proper selection installation and use of non Yamaha accessories You should use extreme caution when selecting and installing any acces sories Keep in mind these guidelines for mounting accessories in addition to those provided under LOADING 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 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 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 1 6 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 motorcy cle may become unstable in cross winds These accessories may also cause insta bility when being p
55. ition 2 1 EABOO0600 OFF All electrical circuits are switched off The key can be removed in this position EAB04303 P Parking The meter light taillight and front position light come on but all other circuits are off With the key at OFF push it into the main switch turn it counterclockwise to P and remove it To cancel the parking turn the key clockwise EAB10000 Indicator lights 1 Push 2 Release 3 Turn EUU08800 NOTE Always turn the main switch to OFF and remove the key when the motorcycle Is un attended Neutral indicator light NEUTRAL Turn indicator light TURN Fuel indicator light FUEL Oil level indicator light OIL LEVEL 5 High beam indicator light HIGH BEAM EAB12403 Turn indicator light TURN This indicator flashes when the turn switch is moved to the left or right PWN EAB10201 Neutral indicator light NEUTRAL This indicator comes on when the trans mission is in neutral EAB10301 High beam indicator light HIGH BEAM This indicator comes on when the head light high beam is used EAB10702 Oil level indicator light OIL LEVEL This indicator comes on when the oil level is low This light circuit can be checked by the following procedure EUU30000 it has sufficient engine oil EUU20900 NOTE a ee Even if the oil is filled to the specified level the indicator light may flicker when riding on a slop
56. k a Yamaha dealer to make that adjustment EAJ80202 Front wheel removal 1 Speedometer cable 2 Caliper bolt x 2 3 Pinch bolt 4 Wheel axle EUUG6202 4 WARNING It is advisable to have a Yamaha dealer service the wheel Securely support the motorcycle so there is no danger of it falling over Place the motorcycle on the center stand Remove the speedometer cable from the front wheel side Remove the caliper bolts and then the calipers 4 Loosen the pinch bolt and wheel axle 5 Elevate the front wheel by placing a suitable stand under the engine 6 Remove the wheel axle Make sure the motorcycle is properly supported EUU05401 c Do depress the brake lever when the disc and caliper are separated 5 47 EAJ29802 Front wheel installation When installing the front wheel reverse 3 Make sure the slot in the speedometer the removal procedure Pay attention to gear unit fits over the stopper on the the following points front fork 1 Make sure the wheel hub and the 4 Tighten the following parts to the speedometer clutch assembly are in specified torque stalled with the projections meshed into the slots 2 Make sure there is enough gap be tween the brake pads before setting the calipers or discs 5 48 Tightening torque Axle 58 Nm 5 8 m kg 42 ft lb Caliper bolt 40 Nm 4 0 m kg 29 ft Ib Before tightening the pinch bolt push
57. l hose and vacuum pipe for cracks or damage Replace if necessary Replace initial 31 000 km 19 600 mi and thereafter every Replace 30 000 km 19 000 mi Check for leakage Retighten if necessary Replace gaskets if necessary Carburetor Adjust synchronization of Synchronization carburetors Check and adjust engine idle speed Adjust cable free play Idle speed ODOMETER READINGS 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or Evaporative emission control system Check control system for damage Replace if necessary Items marked with an asterisk require special tools data and technical skills for servicing Take the motorcycle to a Yamaha Dealer or refer to the Service Manual when servicing these items For California NOTB e o ei ee ee For odometer readings or time periods higher than 31 000 km 19 600 mi or 31 months re peat the same maintenance as listed in the table from the 7 000 km 4 400 mi or 7 months every 6 000 km 3 800 mi or 6 month interval 5 4 GENERAL MAINTENANCE LUBRICATION INITIAL ODOMETER READINGS 1 000 km 7 000 km 13 000 km 19 000 km 25 000 km 31 000 km ITEM ROUTINE TYPE 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or 1 month 7 months 13 months 19 months 25 months 31 months
58. nd polish themselves to the correct oper ating clearances During this period pro longed full throttle operation or any condition which might result in excessive heating of the engine must be avoided EAF30502 1 0 150 km 0 90 mi Avoid operation above 1 000 r min Stop the engine and let it cool for 5 to 10 minutes after every hour of opera tion Vary the speed of the motorcycle from time to time Do not operate it at one set throttle position 2 150 500 km 90 300 mi Avoid prolonged operation above 6 500 r min Rev the motorcycle freely through the gears but do not use full throttle at any time 3 500 1 000 km 300 600 mi Avoid prolonged full throttle opera tion Avoid cruising speeds in excess of 8 000 r min EUUS1801 After 1 000 km 600 mi of operation be sure to replace the engine oil filter and final gear oil 1 000 km 600 mi and beyond Full throttle can be used EUU38701 e Never let engine speeds enter the red Zone e any engine trouble should occur during the break in period consult a Yamaha dealer immediately EAF40001 Parking When parking the motorcycle stop the en gine and remove the ignition key EUU63001 WARNING The exhaust system is hot Park the mo torcycle in a place where pedestrians or children are not likely to touch the motor cycle Do not park the motorcycle on a slope or soft ground the motorcycle may overturn 4 10
59. ndividual problems between you your dealer or YAMAHA MOTOR CORP 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 Transpor tation Washington D C 20590 You can also obtain other information about motor vehicle safety from the Hotline 8 1 EAL00300 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED Federal law prohibits the following acts or the causing thereof 1 The removal or render ing inoperative by any person other than for purposes of maintenance repair or replace ment 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 ren dered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LIST ED BELOW These acts include tampering with the following systems i e modification removal etc Muffler Exhaust system Exhaust pipe Silencer Air cleaner case Intake system Air cleaner element Intake duct 8 2 EALO00501 MAINTENANCE RECORD Copies of work orders and or receipts for parts you purchase and install will be required to document that maintenance has been completed in accordance with the emission warran
60. nsmission seals and electrical parts Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin operated car washers 4 After riding on salted roads wash the motorcycle with cold water immedi ately Do not use warm water as it in creases the chemical reaction of the salt 5 Once the majority of the dirt has been hosed off wash all surfaces with warm water and mild detergent type soap An old toothbrush or bottle brush is handy for hard to get at plac es 6 Rinse the motorcycle off immediately with clean water and dry all surfaces with a chamois clean towel or soft absorbent cloth Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy Automotive type wax may be applied to all painted and chrome plated sur faces Avoid combination cleaner waxes Many contain abrasives which may mar the paint or protective finish When finished start the engine and let it idle for several minutes 6 2 EAK02404 B STORAGE Long term storage 60 days or more of your motorcycle will require some preven tive procedures to guard against deteriora tion After thoroughly cleaning the motorcycle prepare for storage as follows 1 Fill the fuel tank with fuel and add fuel stabilizer if available 2 Remove the spark plugs pour about one tablespoon of SAE 10W30 or 20W40 motor oil in each spark plug hole and reinstall the spa
61. nt Yamaha Chain and Cable Lube or Yamaha Chain and Cable Lube or SAE 10W30 motor oil SAE 10W30 motor oil 5 35 EAI30902 Center and sidestand lubrication Lubricate the pivoting and mating joints Check to see that the center and sidestand move up and down smoothly Recommended lubricant Yamaha Chain and Cable Lube or SAE 10W30 motor oil EUUG9301 WARNING If the center and or sidestand does not move smoothly consult a Yamaha dealer 5 36 EAI31301 Rear suspension lubrication Lubricate the pivoting parts Recommended lubricant Lithium soap base grease EAI20502 Front fork inspection EUU65700 WARNING Securely support the motorcycle so there is no danger of it falling over 1 Visual check Check for scratches or damage on the inner tube and excessive oil leakage from the front fork 2 Operation check Place the motorcycle on a level place 5 37 a Hold the motorcycle in an upright po sition and apply the front brake b Push down hard on the handlebars several times and check if the fork re bounds smoothly EUU42500 If any damage or unsmooth movement is found with the front fork consult a Yamaha dealer EAI60301 Steering inspection Periodically inspect the condition of the steering Worn out or loose steering bear ings may be dangerous Place a stand un der the engine to raise the front wheel off the ground Hold the lower end of the front forks and try
62. o make procedures easier or clear er UU00001 NOTE e This manual should be considered a permanent part of this motorcycle and should main with it even if the motorcycle is subsequently sold e Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your motorcycle and this man ual If there is any question concerning this manual please consult your Yamaha dealer EUU60001 44 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 A SATIS FACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR IN SPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MOTORCYCLE AFFIX DEALER LABEL HERE EAAO00000 VMX12K VMX12KC OWNER S MANUAL 1997 by Yamaha Motor Corporation U S A 1st Edition April 1997 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 10 82 EAA30001 CONTENTS SAFE
63. o release the lock reverse the above procedure 2 14 EAC50001 Helmet holder 1 Helmet holder To open the helmet holder tnsert the key in the lock and turn it as shown To lock the helmet holder replace the holder in its Original position EUU72900 WARNING Never ride with a helmet in the helmet holder The helmet may hit objects caus ing loss of control and possibly an acci dent EAI50503 Front fork adjustment This front fork is equipped with a spring preload adjuster EUU66902 4A WARNING Each fork leg must be set to the same pressure Uneven setting can cause poor handling and loss of stability Adjust spring preload as follows The front fork spring preload is adjusted by changing the air pressure 2 15 1 Elevate the front wheel by placing the motorcycle on the centerstand EUU05001 2 In order check or adjust the air pressure the motorcycle must be elevated so the front wheel is not in contact with the ground 2 Remove the valve cap from each fork leg 1 Air check gauge 3 Using the air check gauge check and adjust the air pressure Increasing the air pressure increases the spring pre load and decreasing it decreases spring preload To increase Use an air pump or pressurized air supply To decrease Release the air by pushing the valve 2 16 EUUO5102 NOTE e An optional air check gauge is available Please consult with a nearby Yama
64. o start out and accelerate 4 7 Front brake lever free play deeelerate isse ri mpi 4 7 shrews d DR RO Qe Qiu 5 28 Rear brake pedal height adjustment sos 5 29 Brake light switch adjustment 5 30 Checking the front and rear Drake 5 30 Inspecting the brake fluid level 5 31 Brake fluid replacement 5 33 Clutch lever free play adjustment 5 33 Cable inspection and lubrication 5 34 Throttle cable and grip lubrication 5 34 Brake and shift pedal lubrication 5 35 Brake and clutch lever lubrication 5 35 Center and sidestand lubrication 5 36 Rear suspension lubrication 5 36 Front fork inspection 5 37 Steering 5 38 Wheel bearings 5 38 Battery Du bu aos daba 5 39 Fuse replacement 5 43 Headlight bulb replacement 5 45 Front wheel removal 5 47 Front wheel installation 5 48 Rear wheel removal 5 49 Rear wheel installation 5 51 Troubleshooting 5 52 Troubleshooting chart 5 53 CLEANING AND STORAGE 6 1
65. ontact the ground and distract the opera tor resulting in a possible loss of control Yamaha has designed into this motorcycle a lockout system to assist the operator in fulfilling the responsibility of retracting the sidestand Please check carefully the operating instructions listed below and if there is any indication of a malfunction re turn the motorcycle to a Yamaha dealer immediately for repair 2 21 EAD30202 Sidestand clutch switch operation check Check the operation of the sidestand switch and clutch switch against the infor mation below EUU69001 4 WARNING e Be sure to use the centerstand during this inspection SIDESTAND IS DOWN e If improper operation is noted con sult a Yamaha dealer ENGINE WILL START CLUTCH SWITCH IS OK ENGINE WILL STALL TURN MAIN SWITCH ON AND ENGINE STOP SWITCH TO RUN SIDESTAND SWITCH IS OK TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL IN CLUTCH LEVER AND PUSH START SWITCH 2 22 EAE00001 PRE OPERATION CHECKS Owners are personally responsible for their vehicle s condition Your motorcycle s vital functions can start to deteriorate quickly and unexpectedly even if it remains unused for instance if it is exposed to the elements Any damage fluid leak or loss of tire pressure could have serious consequences Therefore it is very important that in addition to a thor ough visual inspection you check the following points before each ride
66. otorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of acci dent Therefore a Wear a brightly colored jacket b Use extra caution when you approach and pass through intersections since inter sections are the most likely places for motorcycle accidents c Ride where other motorists can see you Avoid riding in another motorist s blind spot 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 you are qualified Also only lend your motorcycle to experienced op erators b Know your skills and limits Staying within your limits may help you to avoid an accident c Werecommend that you practice riding your motorcycle where there is no traffic until you have become thoroughly familiar with your motorcycle and all of its controls Many motorcycle accidents have been caused by motorcycle operator errors typ ical 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 limits and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure other motorists see you The operator s and passenger s posture are important for proper control a The operator should keep both hands on the handlebars
67. overed repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs covered service replacement vehicle rental emergency towing phone calls even food and lodging when you are away from home This superb coverage goes into effect when you purchase Y E S so it applies to any warranty repairs as well as covered repairs during your entire Y E S plan period Y E S coverage is honored at any authorized Yamaha dealer nationwide Y E S coverage is transferrable to a new owner if you sell or trade in That can make your Yamaha much more valuable This excellent Y E S plan coverage is only available to Yamaha owners like you and only while your Yamaha is still within the Yamaha Limited Warranty period So visit your authorized Yamaha dealer to get all the facts He can show you how easy it is to protect your investment with Yamaha Extended Service 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 You can also save money Y E S costs less within the first 90 days after you buy your Yamaha See your dealer today A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your engine number We ll be happy to help you get the Y E S coverage you need
68. owner with the necessary information for completing some of your own preventive maintenance and minor repairs The tools provided in the owner s tool kit are to as sist you in the performance of periodic maintenance However some other tools such as a torque wrench are also neces sary to perform the maintenance correctly 5 2 EUU 18500 NOTE c If you do not have necessary tools required during a service operation take your mo torcycle to a Yamaha dealer for service EUU63301 4 WARNING Modifications to this motorcycle not ap proved by Yamaha may cause loss of per formance excessive emissions and render it unsafe for use Consult a Yamaha dealer before attempting any changes PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM 1 000 km ODOMETER READINGS 13 000 km 19 000 km 25 000 km 31 000 km 7 000 km 600 mi 4 400 mi 8 200 mi 12 000 mi 15 800 mi 19 600 mi or or or or or or 1 month 7 months 13 months 19 months 25 months 31 months Check and adjust valve clearance when engine is cold Every 42 000 km 26 600 mi or 42 month Check condition Adjust gap and clean Replace at 13 000 km or 13 Replace Replace months and thereafter every 12 000 km or 12 months Crankcase Check ventilation hose for ventilation cracks or damage system Replace if necessary Check fue
69. r tank cap 2 Maximum level mark FULL 3 Minimum level mark LOW Check the coolant level in the reservoir tank when the engine is cold The coolant level will vary with engine temperature The coolant level is satisfactory if it is be tween the minimum and maximum marks on the tank If the coolant level is at or be low the minimum mark fill with tap water soft water to bring the level up to the maximum mark Change the coolant every two years See page 5 19 for details EUU62600 WARNING Do not remove the radiator cap when the engine is hot EUU30900 Hard water or salt water is harmful to the engine You may use distilled water if you can t get soft water Reservoir tank capacity 0 3 L 0 26 Imp qt 0 32 US qt 36 EAE90103 Tires To ensure maximum performance long service and safe operation note the fol lowing 1 Tire air pressure Always check and adjust the tire pres sure before operating the motorcycle EUU67500 WARNING Tire inflation pressure should be checked and adjusted when the temperature of the tire equals the ambient air temperature Tire inflation pressure must be adjusted according to total weight of cargo rider passenger and accessories fairing sad dlebags etc if approved for this model and vehicle speed 3 7 216 kg 476 Ib VMX12 215 kg 474 Ib VMX12C Maximum load Up to 90kg 198 Ib load 2 25 kgf cm 2 25 kgf cm 25
70. rclockwise and remove it Engine overheating Check the cooling system for leakage Wait until the engine has cooled Refer to preced ing WARNING Ask a Yamaha No leakage Add coolant See NOTE INCOR RECT Check the coolant level in the reservoir tank and or radiator dealer to inspect and repair CORRECT Restart the engine If the engine overheats again ask a Yamaha dealer to inspect and repair it EUUO4300 NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the rec ommended coolant as soon as possible 5 20 1 Right cover 2 Changing the coolant ENGINE a Place a container under the engine b Remove the top cover and right cover Br SN 1 Radiator 1 Coolant drain cock c Remove the radiator cap d Turn the coolant drain cock to the ON position exes eee 1 Coolant drain 1 Cover e Remove the drain bolt at the pump CYLINDER cover and drain the coolant a Remove the covers 1 Rubber plug b 3 a Remove the rubber plugs and drain the coolant Coolant filling procedure Drain the coolant completely and thoroughly flush the cooling system with clean tap water Checkthe drain bolt gasket and rubber plugs for damage If damaged replace as necessary Install the drain bolt with the gasket and rubber plug
71. refer to the Service Manual for correct tighten ing torque EAE71500 Lights signals and switches Check all the lights meter lights and indi cator lights to make sure they are in work ing condition Check the operation of the handlebar switches and main switch EAE70502 Battery Check the fluid level and fill if necessary Use only distilled water if refilling is neces sary See page 5 39 for details EAE80000 Fuel EUU39302 Always wipe off spilled fuel immediately with a dry and clean soft cloth Fuel may deteriorate painted surfaces or plastic parts 1 Filler tube 2 Fuel level Make sure there is sufficient fuel in the tank EUUG1000 A WARNING Do not overfill the fuel tank Avoid spilling fuel on the hot engine Do not fill the fuel tank above the bottom of the filler tube as shown in the illustration or it may over flow when the fuel heats up later and ex pands 3 13 EAE81701 Recommended fuel UNLEADED FUEL Fuel tank capacity Total 15 L 3 3 Imp gal 4 0 US gal Reserve 3 L 0 7 Imp gal 0 8 US gal Your Yamaha engine has been designed to use regular unleaded gasoline with a pump octane number R M 2 of 86 or higher or research octane number of 91 or higher If knocking or pinging occurs use a different brand of gasoline or premium un leaded fuel Unleaded fuel will give you longer spark plug life and reduced mainte nance cost unleaded gasoline is not availa
72. rk plugs Turn the engine over several times ground spark plug leads to coat the cylinder walls with oil EUU66400 WARNING When using the starter motor to crank the engine remove the spark plug wires and ground them to prevent sparking 3 Lubricate all control cables 4 Block up the frame to raise both wheels off the ground 5 Tie aplastic bag over the exhaust pipe outlets to prevent moisture from en tering 6 storing in a humid or salt air atmo sphere coat all exposed metal surfac es with a light film of oil Do not apply oil to any rubber parts or the seat cov er 7 Remove the battery and fully charge it Store it in a cool dry place and com pletely recharge it once a month Do not store the battery in an excessively warm or cold place less than 0 C 30 F or more than 30 C 90 F See page 5 40 for battery storage precau tions EUU05800 Make any necessary repairs before storing the motorcycle 6 3 SPECIFICATIONS _ Dimensions Overall length 2 300 mm 90 6 in Overall width 795 mm 31 3 in Overall height 1 160 mm 45 7 in Seat height 765 mm 30 1 in Wheelbase 1 590 mm 62 6 in Minimum ground clearance 145 mm 5 7 in Minimum turning radius 2 900 mm 114 2 in Basic weight with oil and full fuel tank 283 kg 624 Ib VMX12 284 kg 626 16 VMX12C Engine Engine type Liquid cooled 4 stroke gasoline DOHC Cylinder arrangement V type 4 cylind
73. s 5 23 Tightening torque Drain bolt 43 Nm 4 3 m kg 31 ft lb d Pour the recommended coolant into the radiator until it s full Recommended coolant High quality ethylene glycol anti freeze containing corrosion inhibitors for aluminum engines Antifreeze and water mix ratio 5070 5096 Total amount 3 05 L 2 68 Imp qt 3 22 US qt Reservoir tank capacity 0 3 L 0 26 Imp at 0 32 US qt From the minimum to maximum levels 0 2 L 0 18 Imp qt 0 21 US qt EUU30900 Hard water or salt water is harmful to the engine You may use distilled water if you can t get soft water e Reinstall radiator cap and covers f Run the engine several minutes and recheck the coolant level in the radia tor If it is low add more coolant until it reaches the top of the radiator Turn the coolant drain cock to the OFF position 5 24 2 Maximum level mark FULL 1 Coolant reservoir tank cap 3 Minimum level mark LOW h Fill the reservoir tank with coolant up to maximum level i Reinstall the reservoir tank cap and check for coolant leakage EUUO4400 NOTE PT If you find any leaks ask a Yamaha dealer to inspect J Reinstall the right cover and top cover EAH70003 Radiator fan EAH62204 Air filter 1 Engine temperature gauge 2 Red zone Operation The radiator fan operation is completely automatic It is switched on or off accord ing to the coolant temperature in the r
74. s overheated do not continue riding 2 8 EAB60000 Handlebar switches 4 Engine stop switch ENGINE STOP 5 Fuel reserve switch FUEL 6 Start switch START 1 Dimmer switch LIGHTS 2 Turn signal switch TURN 3 Horn switch HORN EAB60101 Dimmer switch LIGHTS Turn the switch to HI for the high beam and to LO for the low beam EAB60301 Turn signal switch TURN This model is equipped with self cancel ling turn signals To signal a right hand turn push the switch to the right To signal a left hand turn push the switch to the left Once the switch is released it will return to the center position To cancel the signal push the switch in after it has returned to the center position If the switch is not can celled by hand it will self cancel after the motorcycle has travelled for about 15 sec onds or approximately 150 m 490 ft whichever is greater The self cancelling mechanism only operates when the mo torcycle is moving Therefore the signal will not self cancel while you are stopped at an intersection 2 9 EAB60201 Horn switch HORN Press the switch to sound the horn EAB60902 Engine stop switch ENGINE STOP The engine stop switch is a safety device for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system Turn the switch to RUN to start the engine In case of emer gency turn the switch to OFF to stop the eng
75. tion Right hand operation type Single disc brake operation Right foot operation Suspension Telescopic fork Swingarm Shock absorber Coil air spring oil Damper Coil spring oil damper Wheel travel 140 mm 5 5 in 100 mm 3 9 in 7 4 Electrical Ignition system T C l digital Generator system A C generator Battery type YB16AL A2 Battery capacity 12 V 16 AH Headlight type Quartz bulb Bulb voltage wattage x quantity Headlight Tail brake light Front turn signal position light Rear turn signal light Meter light Indicator light voltage wattage x quantity 12 V 60 W 55 W x 1 12 V 8W 27W x1 12V 27W 8W x2 12V 27W x2 12V 3W x4 Neutral indicator light 12V 3W x 1 High beam indicator light 12V 3W x 1 Oil level indicator light 12V 3Wx 1 Turn indicator light 12V 3W x 1 Fuel indicator light 12V 3W x 1 7 5 EAL10100 CONSUMER INFORMATION EALO0900 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 Administra tion NHTSA in addition to notifying YAMAHA MOTOR CORP 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 i
76. tion number and model la bel information in the spaces provided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen 1 KEY IDENTIFICATION NUMBER 2 VEHICLE IDENTIFICATION NUMBER ae 3 MODEL LABEL INFORMATION 1 14 EAA61400 Key identification number 1 Key identification number The key identification number is stamped on the key Record this number in the space provided and use it for reference when obtaining a new key EAA80000 Vehicle identification number EAA61602 IModel label 1 Vehicle identification number The vehicle identification number is stamped into the steering head pipe EUU00400 The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state 1 Model label The model label is affixed to the location shown in the figure Record the informa tion on this label in the space provided This information will be needed to order spare parts from your Yamaha dealer EABOO000 CONTROL FUNCTIONS EAB00100 Main switch The main switch controls the ignition and lighting systems Its operation is described below EAB04800 ON All electrical circuits are switched on and the headlight meter light taillight and front position lights come on The engine can be started The key cannot be removed in this pos
77. to move them forward and backward If any free play can be felt ask a Yamaha dealer to inspect and adjust the steering Inspection is easier if the front wheel is removed EUU65700 WARNING Securely support the motorcycle so there is no danger of it falling over 5 38 EAI60103 Wheel bearings If there is play in the front or rear wheel hub or if the wheel does not turn smooth ly have a Yamaha dealer inspect the wheel bearings The wheel bearings should be inspected according to the Gen eral Maintenance Schedule EAI71105 Battery Battery Battery breather hose Pass through the guide Pass through the clamp Check the level of the battery electrolyte and make sure that the terminals are tight Fill with distilled water if the electrolyte level is low EUU33602 When inspecting the battery be sure the breather hose is routed correctly If the breather hose is positioned in such a way as to cause battery electrolyte or gas to exit onto the frame structural and cosmet ic damage to the motorcycle can occur EUU65800 WARNING Battery electrolyte is poisonous and dan gerous causing severe burns etc It con tains sulfuric acid Avoid contact with skin eyes or clothing Antidote EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call a physi cian immediately _ EYES Flush with wat
78. ty The chart below is printed only as a reminder to you that the maintenance work is re quired It is not acceptable proof of maintenance work 1 000km 600 mior 1 mo 7 000km 4 400mior 7 mos 13 000km 8 200mior 13 mos 19 000km 12 000mior 19 mos 25 000km 15 800mior 25 mos 8 3 MAINTENANCE DATE OF SERVICING DEALER INTERVAL SERVICE ME NAME AND ADDRESS 31 000km 19 600 mior 31 mos 37 000km 23 400mior 3 mos 43 000km 27 200mior A3 mos 49 000km 31 000mior 49 mos 55 000km 34 800mior 55 mos 61 000km 38 600 mior 61 mos 8 4 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation U S A hereby warrants each new street or enduro model Yamaha motorcycle purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations THE PERIOD OF WARRANTY for Yamaha motorcycles originally equipped with headlight stoplight and turn signals shall be one 1 year from the date of purchase with no mileage limitation MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leas ing or other commercial purposes and TZ models DURING THE PERIOD OF WARRANTY any authorized Yamaha motorcycle dealer will free of charge repair or replace at Yamah
79. ver then push the start switch Fuel indicator light Fuel indicator light Fuel level Fuel level comes on does not come on is OK is low Fuel level and electrical Ask a Yamaha dealer to Supply fuel circuit are OK inspect electrical circuit i Go ahead with riding 2 6 EAB40005 EAB40200 Speedometer Tachometer 1 Reset knob 2 Odometer 3 Trip odometer 1 Red zone The speedometer shows riding speed This model is equipped with an electric ta This speedometer is equipped with an chometer so the rider can monitor the en odometer and trip odometer The trip gine speed and keep it within the ideal odometer can be reset to 0 with the re power range set knob Use the trip odometer to esti EUU30400 mate how far you can ride on a tank of fuel This information will enable you to plan fuel stops in the future ete eta e e eT a a a e atate e e e cate e se P tut 60 e e ete e e e e o aT ee a eo oe ee ee TNNT ee 8 ee ew 8 8 ey ge Do not operate in the red zone Red zone 9 500 r min and above 2 7 EAB50102 Engine temperature gauge 1 Engine temperature gauge 2 Red zone This gauge indicates the coolant tempera ture when the main switch is on The en gine operating temperature will vary with changes in weather and engine load If the needle points to the red zone or higher stop your motorcycle and let the engine cool See page 5 19 for details EUU30500 When the engine i

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