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Yamaha VMAX VMX12 Owner'S Manual Download Page 44

6-1

6

EAU00462

6-

PERIODIC MAINTENANCE AND MINOR REPAIR 

EAU00464

Safety is an obligation of the owner.
Periodic inspection, adjustment and lu-
brication will keep your vehicle in the
safest and most efficient condition pos-
sible. The most important points of in-
spection, adjustment, and lubrication
are explained on the following pages.
The intervals given in the periodic
maintenance and lubrication chart
should be simply considered as a gen-
eral guide under normal riding condi-
tions. However, DEPENDING ON THE
WEATHER, TERRAIN, GEOGRAPHI-
CAL LOCATION, AND INDIVIDUAL
USE, THE MAINTENANCE INTER-
VALS MAY NEED TO BE SHORT-
ENED.

EW000060

WARNING

@ 

If you are not familiar with motor-
cycle maintenance work, have a
Yamaha dealer do it for you. 

@

EAU01659

Owner’s tool kit 

The tool kit is located inside the storage
compartment behind the rider seat
backrest. (See page 3-9 for an expla-
nation on moving the rider seat back-
rest forward and back.)

The service information included in this
manual and the tools provided in the
owner’s tool kit are intended to assist
you in the performance of preventive
maintenance and minor repairs. How-
ever, additional tools such as a torque
wrench may be necessary to perform
certain maintenance work correctly.

NOTE:

@ 

If you do not have the tools or experi-
ence required for a particular job, have
a Yamaha dealer perform it for you. 

@

1. Owner’s tool kit
2. Rider seat backrest

E_3lr.book  Page 1  Wednesday, November 22, 2000  4:10 PM

Summary of Contents for VMAX VMX12

Page 1: ...3LR 28199 E3 OWNER S MANUAL VMX12 ...

Page 2: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 3: ... enjoy all advantages of your VMX12 The owner s manual does not only instruct you in how to operate inspect and maintain your motorcycle but also in how to safeguard yourself and oth ers from trouble and injury In addition the many tips given in this manual will help keep your motorcycle in the best possible condition If you have any further questions do not hesitate to contact your Yamaha dealer ...

Page 4: ...be taken to avoid damage to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer NOTE This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold Yamaha continually seeks advancements in product design and quality Therefore while this manual contains the most current product informati...

Page 5: ...IMPORTANT MANUAL INFORMATION EW000002 WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE E_3lr book Page 2 Wednesday November 22 2000 4 10 PM ...

Page 6: ...UAL 2000 by Yamaha Motor Co Ltd 1st Edition April 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan E_3lr book Page 3 Wednesday November 22 2000 4 10 PM ...

Page 7: ...NT AND CONTROL FUNCTIONS 3 4 PRE OPERATION CHECKS 4 5 OPERATION AND IMPORTANT RIDING POINTS 5 6 PERIODIC MAINTENANCE AND MINOR REPAIR 6 7 MOTORCYCLE CARE AND STORAGE 7 8 SPECIFICATIONS 8 9 CONSUMER INFORMATION 9 INDEX EAU00009 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 8: ...E_3lr book Page 2 Wednesday November 22 2000 4 10 PM ...

Page 9: ...GIVE SAFETY THE RIGHT OF WAY 1 GIVE SAFETY THE RIGHT OF WAY 1 1 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 10: ...even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Always wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protectors sturdy boots motorcycle gloves and a properly fitting helmet Optimum protective wear however should...

Page 11: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 12: ...box page 6 37 4 Main fuse box page 6 37 5 Owner s tool kit page 6 1 6 Rear shock absorber spring preload adjusting ring page 3 13 7 Rear shock absorber damping force adjusting knob page 3 13 8 Helmet holder page 3 10 9 Shift pedal page 3 6 10 Starter choke lever page 3 8 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 13: ...nt brake master cylinder reservoir page 6 27 15 Main switch page 3 1 16 Radiator cap page 6 16 17 Radiator page 6 16 18 Engine oil filter cartridge page 6 9 19 Engine oil level check window page 6 9 20 Brake pedal page 3 6 21 Rear brake fluid reservoir page 6 27 E_3lr book Page 2 Wednesday November 22 2000 4 10 PM ...

Page 14: ... 3 5 2 Left handlebar switches page 3 4 3 Speedometer unit page 3 2 4 Right handlebar switches page 3 4 5 Brake lever page 3 6 6 Throttle grip page 6 21 7 Tachometer page 3 3 8 Coolant temperature gauge page 3 3 E_3lr book Page 3 Wednesday November 22 2000 4 10 PM ...

Page 15: ...4 Clutch lever 3 5 Shift pedal 3 6 Brake lever 3 6 Brake pedal 3 6 Fuel tank cap 3 7 Fuel 3 8 Starter choke lever 3 8 Steering lock 3 9 Rider seat 3 9 Helmet holder 3 10 Adjusting the front fork 3 11 Adjusting the shock absorber assemblies 3 12 Matching the front and rear suspension settings 3 15 Sidestand 3 16 Ignition circuit cut off system 3 16 E_3lr book Page 1 Wednesday November 22 2000 4 10 ...

Page 16: ...emoved The key must be pushed in and then released before it can be turned to P ECA00043 CAUTION Do not use the parking position for an extended length of time other wise the battery may discharge EAU03034 Indicator and warning lights EAU00061 Neutral indicator light This indicator light comes on when the transmission is in the neutral position EAU00057 Turn signal indicator light This indicator l...

Page 17: ...warning light does not come on have a Yamaha dealer check the electrical circuit NOTE Even if the oil level is sufficient the warning light may flicker when riding on a slope or during sudden acceleration or deceleration but this is not a mal function EAU00095 Speedometer unit The speedometer unit is equipped with a speedometer an odometer and a tripmeter The speedometer shows riding speed The odo...

Page 18: ...amaha dealer Contact a Yamaha dealer for more information EAU01652 Coolant temperature gauge With the key in the ON position the coolant temperature gauge indicates the temperature of the coolant The coolant temperature varies with chang es in the weather and engine load If the needle reaches or enters the red zone stop the motorcycle and let the engine cool See page 6 46 for further instructions ...

Page 19: ...lso be canceled manually by pushing the switch in after it has returned to the center position NOTE The self canceling system only oper ates when the motorcycle is moving so that the turn signal lights will not self cancel while you are stopped at an in tersection EAU00129 Horn switch Press this switch to sound the horn EAU00138 Engine stop switch Set this switch to to stop the en gine in case of ...

Page 20: ...witching to RES approximately 3 L of fuel remain in the fuel tank EAU00152 Clutch lever The clutch lever is located at the left handlebar grip To disengage the clutch pull the lever toward the handle bar grip To engage the clutch release the lever The lever should be pulled rapidly and released slowly for smooth clutch operation The clutch lever is equipped with a clutch switch which is part of th...

Page 21: ...nt mesh transmission equipped on this motorcycle EAU00158 Brake lever The brake lever is located at the right handlebar grip To apply the front brake pull the lever toward the handle bar grip EAU00162 Brake pedal The brake pedal is on the right side of the motorcycle To apply the rear brake press down on the brake pedal 1 Shift pedal 1 Brake lever 1 Brake pedal E_3lr book Page 6 Wednesday November...

Page 22: ...ned To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock 2 Turn the key counterclockwise and then remove it 3 Slide the rider seat backrest rear ward and push it down NOTE The fuel tank cap cannot be installed unless the key is in the lock In addition the key cannot be removed if the cap is not properly installed and locked EW000024 WARNIN...

Page 23: ...ate painted surfac es or plastic parts EAU00191 NOTE If knocking or pinging occurs use gasoline of a different brand or with a higher octane grade EAU02976 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by the starter choke Move the lever in direction a to turn on the starter choke Move the lever in direction b to turn off the starter choke 1 Filler...

Page 24: ... the steering is locked remove the key and then close the lock cover To unlock the steering 1 Open the steering lock cover and then insert the steering lock steer ing lock key 2 Push the key in turn it 1 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover EAU03413 Rider seat To remove the rider seat 1 Release the rider seat backrest by pu...

Page 25: ...ured before riding 3 Return the rider seat backrest to the original position EAU00260 Helmet holder To open the helmet holder insert the key into the lock and then turn the key as shown To lock the helmet holder place it in the original position and then remove the key EW000030 WARNING Never ride with a helmet attached to the helmet holder since the helmet may hit objects causing loss of control a...

Page 26: ...ir pressure there should be no weight on the front end of the motorcycle 2 Remove the air valve cap from each fork leg 3 Check the air pressure in each fork leg with an air pressure gauge NOTE An optional air pressure gauge is avail able at a Yamaha dealer 4 To increase the spring rate and thereby harden the suspension increase the air pressure with an air pump or compressed air To decrease the sp...

Page 27: ... absorber assemblies Both shock absorber assemblies are equipped with a spring preload adjust ing ring and a damping force adjusting knob EC000015 CAUTION Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings EW000040 WARNING Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Spring rate Minimum standard soft ...

Page 28: ...er Use the special wrench included in the owner s tool kit to make this adjustment Damping force To increase the damping force and thereby harden the damping turn the adjusting knob on each shock absorber assembly in direction a To decrease the damping force and thereby soften the damping turn the adjusting knob on each shock absorber assembly in direction b NOTE Align the appropriate setting on t...

Page 29: ...INSTRUMENT AND CONTROL FUNCTIONS 3 14 3 Damping force Minimum soft 1 Standard 1 Maximum hard 4 E_3lr book Page 14 Wednesday November 22 2000 4 10 PM ...

Page 30: ...mpt to turn an adjusting mechanism beyond the maximum or minimum settings Load condition Front fork adjustment Shock absorber assembly adjustment Spring preload air pressure Spring preload Damping force Rider only 40 60 kPa 0 4 0 6 kg cm2 0 4 0 6 bar 1 2 1 2 With passenger or with accessories and equipment 40 100 kPa 0 4 1 0 kg cm2 0 4 1 0 bar 3 5 2 4 With passenger accessories and equipment 40 10...

Page 31: ...ility of raising the side stand before starting off Therefore check this system regularly as de scribed below and have a Yamaha dealer repair it if it does not function properly EAU00332 Ignition circuit cut off system The ignition circuit cut off system com prising the sidestand switch clutch switch and neutral switch has the fol lowing functions It prevents starting when the trans mission is in ...

Page 32: ... clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever pulled 12 Push the start switch Does the engine start The sidestand switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The clutch switch may be defective The motorcycle should...

Page 33: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 34: ...e fluid if necessary 6 25 6 28 Rear brake 6 25 6 28 Clutch Check operation fluid level and for fluid leakage Fill with DOT 4 brake fluid if necessary 6 24 6 27 Throttle grip and housing Check operation Lubricate if necessary 6 21 6 29 Engine oil Check oil level Add oil if necessary 6 9 6 12 Coolant Check coolant level Add coolant if necessary 6 14 6 18 Final gear oil Check vehicle for leakage 6 13...

Page 35: ...tem in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle Chassis fasteners Make sure that all nuts bolts and screws are properly tightened Tighten if necessary Fuel Check fuel level Add fuel if necessary 3 8 Lights signals and switches Check operation Battery Check fluid level Add distilled water if necessary 6 33 6 36 ITEM CHECKS P...

Page 36: ...E_3lr book Page 3 Wednesday November 22 2000 4 10 PM ...

Page 37: ... Starting a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Recommended shift points for Switzerland only 5 4 Tips for reducing fuel consumption 5 4 Engine break in 5 4 Parking 5 5 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 38: ...nable starting one of the following conditions must be met The transmission is in the neutral position The transmission is in gear with the clutch lever pulled and the sidestand up EW000054 WARNING Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 16 Never ride with the sidestand down 1 Turn the key to ON and make ...

Page 39: ...arning light does not come on when push ing the start switch or if it does not go off after starting with suf ficient engine oil have a Yamaha dealer check the elec trical circuit If the fuel level warning light re mains on after starting stop the engine and then check the fuel level If necessary refuel as soon as possible and then check the warning light again If the warning light does not come o...

Page 40: ...n press the shift pedal down repeatedly until it reaches the end of its travel and then slightly raise it EC000048 CAUTION Even with the transmission in the neutral position do not coast for long periods of time with the engine off and do not tow the motorcycle for long dis tances The transmission is properly lubricated only when the engine is running Inade quate lubrication may damage the transmi...

Page 41: ...e shift ing down and avoid high engine speeds with no load on the engine Turn the engine off instead of let ting it idle for an extended length of time e g in traffic jams at traf fic lights or at railroad crossings EAU00436 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1 000 km For this rea son you should read the following ma teri...

Page 42: ...ON After 1 000 km of operation the en gine oil and final gear oil must be changed and the oil filter cartridge replaced 1 000 km and beyond The vehicle can now be operated normally EC000053 CAUTION Keep the engine speed out of the tachometer red zone If any engine trouble should occur during the engine break in period immediately have a Yamaha dealer check the vehicle EAU00460 Parking When parking...

Page 43: ...e light switch 6 26 Checking the front and rear brake pads 6 26 Checking the brake fluid level 6 27 Changing the brake fluid 6 28 Checking and lubricating the cables 6 28 Checking and lubricating the throttle grip and cable 6 29 Checking and lubricating the brake and shift pedals 6 29 Checking and lubricating the brake and clutch levers 6 30 Checking and lubricating the centerstand and sidestand 6...

Page 44: ...EW000060 WARNING If you are not familiar with motor cycle maintenance work have a Yamaha dealer do it for you EAU01659 Owner s tool kit The tool kit is located inside the storage compartment behind the rider seat backrest See page 3 9 for an expla nation on moving the rider seat back rest forward and back The service information included in this manual and the tools provided in the owner s tool ki...

Page 45: ...R 6 2 6 EW000063 WARNING Modifications not approved by Yamaha may cause loss of perfor mance and render the vehicle un safe for use Consult a Yamaha dealer before attempting any changes E_3lr book Page 2 Wednesday November 22 2000 4 10 PM ...

Page 46: ...heck fuel hoses for cracks or damage 2 Fuel filter Check condition 3 Spark plugs Check condition Clean and regap Replace 4 Valves Check valve clearance Adjust 5 Air filter element Clean Replace 6 Battery Check electrolyte level and specific gravity Make sure that the breather hose is properly routed 7 Clutch Check operation fluid level and vehicle for fluid leakage See NOTE on page 6 5 8 Front bra...

Page 47: ...based grease Every 50 000 km 16 Chassis fasteners Make sure that all nuts bolts and screws are properly tightened 17 Sidestand centerstand Check operation Lubricate 18 Sidestand switch Check operation 19 Front fork Check operation and for oil leakage 20 Rear shock absorber assemblies Check operation and shock absorbers for oil leakage 21 Carburetors Check engine idling speed synchronization and st...

Page 48: ...ents of the brake master cylinder and caliper as well as clutch master and release cylinders and change the brake and clutch fluids 25 Final gear oil Check oil level and vehicle for oil leakage Change 26 Front and rear brake switches Check operation 27 Moving parts and cables Lubricate 28 Lights signals and switches Check operation Adjust headlight beam NO ITEM CHECK OR MAINTENANCE JOB ODOMETER RE...

Page 49: ...ds to be re moved and installed EAU03415 Cowling A To remove the cowling 1 Insert the key into the lock and then turn it clockwise 2 Pull the cowling off as shown To install the cowling 1 Align the holders under the cowl ing with the projections on the frame 2 Push down on the rear of the cowl ing until it locks in place 3 Remove the key from the lock 1 Cowling A 2 Panel A 3 Panel B 1 Unlock 1 Hol...

Page 50: ... off To install the panel Place the panel in the original position and then install the screws EAU03329 Checking the spark plugs The spark plugs are important engine components which are easy to check Since heat and deposits will cause any spark plug to slowly erode the spark plugs should be removed and checked in accordance with the periodic mainte nance and lubrication chart In addition the cond...

Page 51: ...ose such problems yourself Instead have a Yamaha dealer check the motorcycle 3 Check each spark plug for elec trode erosion and excessive car bon or other deposits and replace it if necessary To install a spark plug 1 Measure the spark plug gap with a wire thickness gauge and if nec essary adjust the gap to specifica tion 2 Clean the surface of the spark plug gasket and its mating sur face and the...

Page 52: ...vel 1 Place the motorcycle on the cen terstand NOTE Make sure that the motorcycle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading 2 Start the engine warm it up for several minutes and then turn it off 3 Wait a few minutes until the oil set tles and then check the oil level through the check window located at the bottom right side of th...

Page 53: ...ect the used oil 3 Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase NOTE Skip steps 4 6 if the oil filter cartridge is not being replaced 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 1 Engine oil filler cap 1 Engine oil drain bolt 1 Oil filter cartridge 2 Oil filter wrench E_3lr book Page 10...

Page 54: ... bolt and then tighten it to the specified torque 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kg Tightening torque Engine oil drain bolt 43 Nm 4 3 m kg Recommended engine oil See page 8 1 Oil quantity Without oil filter cartridge replacement 3 2 L With oil filter...

Page 55: ...Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking immediately turn the engine off and check for the cause NOTE After the engine is started the engine oil level warning light should go off if the oil level is sufficient EC000067 CAUTION If the oil level warning light flickers or remains on immediately turn the engine off and have a Yamaha ...

Page 56: ...gear oil drain bolt and then tighten it to the specified torque 5 Add the specified amount of the recommended final gear oil and then install and tighten the oil filler bolt NOTE GL4 is a quality rating Hypoid gear oils rated GL5 or GL6 may also be used EW000066 WARNING Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel 6 Check the final ...

Page 57: ...s NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the motorcycle is positioned straight up when checking the coolant level A slight tilt to the side can result in a false reading 3 Check the coolant level in the coolant reservoir NOTE The coolant should be between the minimum and maximum level marks 4 If the coolant is at or bel...

Page 58: ... content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced EW000067 WARNING Never attempt to remove the radia tor cap when the engine is hot NOTE The radiator fan is automatically switched on or off according to the coolant temperature in the radiator If the engine overheats see page 6 46 for further instructions EAU03417 To change the coolant 1 Place th...

Page 59: ...attempt to remove the radia tor cap when the engine is hot 5 Turn the coolant drain cock to ON 6 Remove the water pump drain bolt to drain the water pump housing 1 Radiator cap 1 Coolant drain cock 2 Position indicator 1 Water pump drain bolt E_3lr book Page 16 Wednesday November 22 2000 4 10 PM ...

Page 60: ... specified torque NOTE Check the washer for damage and re place it if necessary 11 Install the rubber coolant drain plugs and then install the cylinder drain plug covers NOTE Check the rubber plugs for damage and replace them if necessary 12 Turn the coolant drain cock to OFF 13 Pour the recommended coolant into the reservoir to the maximum level and then install the cap 14 Pour the recommended co...

Page 61: ...engine let it idle for several min utes and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator If necessary add sufficient coolant until it reaches the top of the radia tor and then install the radiator cap 17 Check the coolant level in the res ervoir If necessary remove the coolant reservoir cap add coolant to the maximum level mark and then install the cap 18 ...

Page 62: ...ment out 4 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 5 Insert the air filter element into the air filter case EC000082 CAUTION Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the ...

Page 63: ...Adjusting the engine idling speed The engine idling speed must be checked and if necessary adjusted as follows at the intervals specified in the periodic maintenance and lubrication chart 1 Start the engine and warm it up for several minutes at 1 000 2 000 r min while occasionally rev ving it to 4 000 5 000 r min NOTE The engine is warm when it quickly re sponds to the throttle 2 Check the engine ...

Page 64: ...d in the periodic maintenance and lubrication chart EAU00647 Tires To ensure maximum performance as well as the long and safe operation of your motorcycle note the following points regarding the specified tires Tire air pressure The tire air pressure should be checked and if necessary adjusted before each ride EW000082 WARNING The tire air pressure must be checked and adjusted on cold tires i e wh...

Page 65: ...ir pressure with regard to the load Check the tire condition and air pressure before each ride Tire inspection The tires must be checked before each ride If the center tread depth reaches the specified limit if the tire has a nail or glass fragments in it or if the side wall is cracked have a Yamaha dealer replace the tire immediately CE 08E NOTE The tire tread depth limits may differ from country...

Page 66: ...isted below have been ap proved for this model by Yamaha Motor Co Ltd CE 10E EAU00684 WARNING This motorcycle is fitted with super high speed tires Note the following points in order to make the most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain road...

Page 67: ...anging a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics After repairing or replacing a tire tighten the valve stem nut and locknut to the specified torques EAU00695 Clutch lever free play Since this model is equipped with a hy draulic clutch adjusting the clutch lever free play is not needed However it is necessary to check the clutch fluid lev ...

Page 68: ...e brake is working properly A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system If there is air in the hy draulic system have a Yamaha dealer bleed the system before operating the motorcycle Air in the hydraulic system will dimin ish the braking performance which may result in loss of con trol and an accident EAU00712 Adjusting the brake pedal posit...

Page 69: ...while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction a To make the brake light come on later turn the adjusting nut in direction b EAU00715 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec ified in the periodic maintenance and lubrication chart Each brake pad...

Page 70: ... ter cylinder is level by turning the handlebars Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Refill with the same type of brake fluid Mixing fluids may result in a harmful chemical reaction and lead to poor braking or clutch per formance The diaphragm will lose its shape from the negative pressure i...

Page 71: ...ell as the brake hose replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake hose Replace every four years EAU02962 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride and the ca bles and cable ends should be lubricat ed if necessary If a cable is d...

Page 72: ... then apply several drops of oil to the cable end allowing it to trickle into the sheath 3 Connect the throttle cable and then grease the inside of the throt tle grip housing 4 Grease the metal to metal contact surface of the throttle grip and then install the grip by installing the screws EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals shou...

Page 73: ...and sidestand The operation of the centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary EW000114 WARNING If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it Recommended lubricant Lithium soap based grease all purpose grease Recommended lubricant Lith...

Page 74: ... WARNING Securely support the motorcycle so that there is no danger of it falling over Check the inner tubes for scratches damage and excessive oil leakage To check the operation 1 Place the motorcycle on a level surface and hold it in an upright position 2 While applying the front brake push down hard on the handle bars several times to check if the front fork compresses and re bounds smoothly EC...

Page 75: ... riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EW000115 WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Hold the lower ends of the front fork legs and try to move them for ward and backward If any free play can be felt have a Yamaha dealer check or repair the steer ing E_3lr book Page 32 Wed...

Page 76: ...ad connections and breather hose routing should be checked before each ride and at the in tervals specified in the periodic mainte nance and lubrication chart To check the electrolyte level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make sure that the motorcycle is posi tioned straight up when checking the electrolyte level 2 Check the electrolyte level in th...

Page 77: ...ct the negative battery lead from the battery 6 Disconnect the positive battery lead and the starter motor lead from the starter motor relay 7 Remove the ignition coil assem blies by removing the bolts 8 Add distilled water to raise the electrolyte to the maximum level mark 1 Bolt 2 2 Screw 2 1 Starter motor lead black 2 Battery positive lead red 3 Ignition coil assembly 2 4 Bolt 2 E_3lr book Page...

Page 78: ...h with water for 15 minutes and seek prompt medical attention Batteries produce explosive hy drogen gas Therefore keep sparks flames cigarettes etc away from the battery and pro vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN EC000100 CAUTION Use only distilled water as tap water contains minerals that are harmful to the b...

Page 79: ...remove the battery fully charge it and then place it in a cool dry place 2 If the battery will be stored for more than two months check the specific gravity of the electrolyte at least once a month and fully charge the battery whenever nec essary 3 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals an...

Page 80: ...n install a new fuse of the specified amperage EC000103 CAUTION Do not use a fuse of a higher amper age rating than recommended to avoid causing extensive damage to the electrical system and possibly a fire 3 Turn the key to ON and turn on the electrical circuit in question to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system 1 Main...

Page 81: ...ht bulb and do not touch the bulb until it has cooled down 4 Place a new bulb into position and then secure it with the bulb holder EC000105 CAUTION Do not touch the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the luminosity of the bulb and the bulb life will be adversely af fected Thoroughly clean off any dirt and fingerprints on the headlight...

Page 82: ...e bulb by pushing it in and turning it counter clockwise 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 4 Install the lens by installing the screws EC000108 CAUTION Do not overtighten the screws oth erwise the lens may break 1 Screw 2 1 Tail brake light bulb 2 1 Turn signal light bulb E_3lr book Page 39 Wednesday November 22 2000 4 10 PM ...

Page 83: ...heel 3 Remove the brake caliper by re moving the bolts ECA00047 CAUTION Do not pull the brake lever after the brake caliper has been removed otherwise the brake pads will be forced shut 4 Loosen the front wheel axle pinch bolt then the wheel axle 5 Pull the wheel axle out and then remove the wheel EAU03420 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that th...

Page 84: ...alipers onto the brake discs 6 Tighten the front wheel axle pinch bolt then the wheel axle and the brake caliper bolts to the specified torques 7 Connect the speedometer cable 8 Push down hard on the handlebar several times to check for proper fork operation EAU03421 Rear wheel To remove the rear wheel EW000122 WARNING It is advisable to have a Yamaha dealer service the wheel Securely support the ...

Page 85: ...e bolt 5 While supporting the brake cali per pull the wheel axle out 6 Remove the brake caliper bracket and spacer 7 Pull the wheel to the right to sepa rate it from the final gear case and then remove it ECA00062 CAUTION Do not push the brake pedal after the wheel has been removed togeth er with the brake disc otherwise the brake pads will be forced shut 1 Pinch bolt 1 Nut 2 Cotter pin 3 Brake to...

Page 86: ...o the brake disc 4 Install the brake torque rod bolt and nut at the brake caliper brack et 5 Install the rear wheel axle nut 6 Take the motorcycle off the cen terstand so that the rear wheel is on the ground 7 Tighten the axle nut brake caliper bolts brake torque rod nut and pinch bolt to the specified torques 8 Install the brake torque rod cotter pin EW000124 WARNING Always use a new cotter pin T...

Page 87: ...troubleshooting charts represent quick and easy procedures for checking these vital systems your self However should your motorcycle require any repair take it to a Yamaha dealer whose skilled technicians have the necessary tools experience and know how to service the motorcycle properly Use only genuine Yamaha replace ment parts Imitation parts may look like Yamaha parts but they are often inferi...

Page 88: ...he vehicle Remove the spark plugs and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle The engine does not start Check the battery Open the throttle halfway and operate the electric starter Operate the electric starter 4 Battery The engine turns over quickly The engine turns over slow...

Page 89: ...iss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap NOTE If coolant is not available tap water can be temporarily used instead provided that it is changed to the recommended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir and radiator The coolant level is OK The coolant level is low Check th...

Page 90: ...E_3lr book Page 47 Wednesday November 22 2000 4 10 PM ...

Page 91: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 92: ... stalled 3 Remove extremely stubborn dirt like oil burnt onto the crankcase with a degreasing agent and a brush but never apply such prod ucts onto seals gaskets and wheel axles Always rinse the dirt and degreaser off with water Cleaning ECA00010 CAUTION Avoid using strong acidic wheel cleaners especially on spoked wheels If such products are used on hard to remove dirt do not leave the cleaner on...

Page 93: ... use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minutes before cleaning After riding in the rain near the sea or on salt sprayed roads Since sea salt or salt sprayed on road...

Page 94: ...inted surfaces 7 Let the motorcycle dry completely before storing or covering it EWA00031 WARNING Make sure that there is no oil or wax on the brakes or tires If necessary clean the brake discs and brake linings with a regular brake disc cleaner or ac etone and wash the tires with warm water and a mild deter gent Before riding at higher speeds test the motorcycle s braking performance and cor neri...

Page 95: ...ent fuel deposits from building up Pour the drained fuel into the fuel tank 4 Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating 5 Perform the following steps to pro tect the cylinders piston rings etc from corrosion a Remove the spark plug caps and spark plugs b Pour a teaspoonful of engine oil into each spark plug bore...

Page 96: ...very month in order to prevent the tires from becoming degraded in one spot 8 Cover the muffler outlets with plas tic bags to prevent moisture from entering them 9 Remove the battery and fully charge it Store it in a cool dry place and charge it once a month Do not store the battery in an ex cessively cold or warm place less than 0 C or more than 30 C For more information on storing the battery se...

Page 97: ...SPECIFICATIONS 8 Specifications 8 1 Conversion table 8 5 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 98: ...starter Lubrication system Wet sump Engine oil Type Recommended engine oil classification API Service SE SF SG or higher Quantity Without oil filter cartridge replacement 3 2 L With oil filter cartridge replacement 3 4 L Total amount dry engine 4 0 L 20 10 0 10 20 30 40 50 C SAE 10W 30 SAE 15W 40 SAE 20W 40 SAE 20W 50 SAE 10W 40 CAUTION Be sure to use motor oils that do not contain anti friction m...

Page 99: ...mm Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 776 Secondary reduction system Shaft drive Secondary reduction ratio 2 567 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 529 2nd 1 773 3rd 1 348 4th 1 077 5th 0 929 Chassis Frame type Double cradle Caster angle 29 Trail 119 mm Tires Front Type Tubeless Size 110 ...

Page 100: ...el Size 18 MT 2 15 Rear Type Cast wheel Size 15M C MT 3 50 Brakes Front Type Dual disc brake Operation Right hand Fluid DOT 4 Rear Type Single disc brake Operation Right foot Fluid DOT 4 Suspension Front Telescopic fork Rear Swingarm Spring shock absorber Front Coil air spring oil damper Rear Coil spring oil damper Wheel travel Front 140 mm Rear 100 mm Electrical system Ignition system T C I digit...

Page 101: ...1 for F B I P Meter lighting 14 V 3 W 2 Neutral indicator light 14 V 3 W 1 High beam indicator light 14 V 3 W 1 Turn signal indicator light 14 V 3 W 1 Fuel level warning light 14 V 3 W 1 Oil level warning light 14 V 3 W 1 Fuses Main fuse 30 A Headlight fuse 15 A Signaling system fuse 10 A Radiator fan fuse 10 A Ignition fuse 10 A E_3lr book Page 4 Wednesday November 22 2000 4 10 PM ...

Page 102: ...tric unit Multiplier Imperial unit Torque m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km h 0 6214 mi h Distance km m m cm mm 0 6214 3 281 1 094 0 3937 0 03937 mi ft yd in in Volume Capacity cc cm3 cc cm3 L liter L liter 0 03527 0 06102 0 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Miscellaneous kg mm kg cm2 Centigrade C 55 ...

Page 103: ...CONSUMER INFORMATION 9 Identification numbers 9 1 Key identification number 9 1 Vehicle identification number 9 1 Model label 9 2 E_3lr book Page 1 Wednesday November 22 2000 4 10 PM ...

Page 104: ...1E EAU01042 Key identification number The key identification number is stamped into the key Record this num ber in the space provided and use it for reference when ordering a new key EAU01043 Vehicle identification number The vehicle identification number is stamped into the steering head pipe Record this number in the space pro vided NOTE The vehicle identification number is used to identify your...

Page 105: ...er cowl ing A See page 6 6 for cowling re moval and installation procedures Record the information on this label in the space provided This information will be needed when ordering spare parts from a Yamaha dealer 1 Model label E_3lr book Page 2 Wednesday November 22 2000 4 10 PM ...

Page 106: ...ne stop switch 3 4 F Final gear oil 6 13 Front fork adjusting 3 11 Front fork checking 6 31 Fuel 3 8 Fuel consumption tips for reducing 5 4 Fuel level warning light 3 2 Fuel reserve switch 3 5 Fuel tank cap 3 7 Fuses replacing 6 37 H Handlebar switches 3 4 Headlight bulb replacing 6 38 Helmet holder 3 10 High beam indicator light 3 2 Horn switch 3 4 I Identification numbers 9 1 Idling speed adjust...

Page 107: ...ting 6 21 Throttle grip and cable checking and lubricating 6 29 Tires 6 21 Tool kit 6 1 Troubleshooting 6 44 Troubleshooting charts 6 45 Turn signal indicator light 3 1 Turn signal light or tail brake light bulb replacing 6 39 Turn signal switch 3 4 V Valve clearance adjusting 6 21 Vehicle identification number 9 1 W Wheel bearings checking 6 33 Wheel front 6 40 Installing 6 40 Removing 6 40 Wheel...

Page 108: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 109: ...H_5KS_Toc0 fm Page 2 Monday August 21 2000 11 11 AM ...

Page 110: ...PRINTED IN JAPAN 2000 10 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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