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Yamaha Vmax VMX12N, Owner'S Manual, Page: 37 / 93

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Yamaha Vmax VMX12N Owner'S Manual Download Page 37

PERIODIC MAINTENANCE AND MINOR REPAIR

I

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.

EW000063

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.

NOTE:

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

6-2

Summary of Contents for Vmax VMX12N

Page 1: ......

Page 2: ...c maintenance of this motorcycle If you have any questions concerning the operation or maintenance of your motorcycle please consult a Yamaha dealer The design and manufacture of this Yamaha motorcycle fully comply with the emis sions standards for clean air applicable at the date of manufacture Yamaha has met these standards without reducing the performance or economy of operation of the motorcyc...

Page 3: ...DE NECESSARY BY MECHANICAL CONDITIONS Safe riding 1 Always make pre operation checks Careful checks may help prevent an accident 2 This motorcycle is designed to carry the operator and a passenger 3 The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not...

Page 4: ...SIVE SPEED or undercornering insufficient lean angle for the speed a Always obey the speed limit and never travel faster than warranted by road and traffic conditions b Always signal before turning or changing lanes Make sure that other motorists can see you 6 The posture of the operator and passenger is important for proper control a The operator should keep both hands on the handlebar and both f...

Page 5: ... during or after operation They become very hot and can cause burns Always wear protective clothing that covers your legs ankles and feet 6 A passenger should also observe the above precautions Modifications Modifications made to this motorcycle not approved by Yamaha or the removal of original equipment may render the motorcycle unsafe for use and may cause severe personal injury Modifications ma...

Page 6: ...k or front fender These items in cluding such items as sleeping bags duffel bags or tents can create unstable handling or a slow steering response Accessories Genuine Yamaha accessories have been specifically designed for use on this motorcycle Since Yamaha cannot test all other accessories that may be available you must personally be responsible for the proper selection installation and use of no...

Page 7: ...may limit control ability therefore such accessories are not recommended Use caution when adding electrical accessories If electrical accessories exceed the capacity of the motorcycle s electrical system an electric failure could result which could cause a dangerous loss of lights or engine power Gasoline and exhaust gas 1 GASOLINE IS HIGHLY FLAMMABLE a Always turn the engine off when refueling b ...

Page 8: ...g a kerosene heater or near an open flame otherwise it could catch fire 4 When transporting the motorcycle in another vehicle make sure that it is kept upright If the motor cycle should lean over gasoline may leak out of the carburetor or fuel tank 5 If you should swallow any gasoline inhale a lot of gasoline vapor or allow gasoline to get into your eyes see your doctor immediately If any gasoline...

Page 9: ...A SAFETY INFORMATION Location of important labels u Please read the following important labels carefully before operating this motorcycle 1 2 3 4 5 A ...

Page 10: ......

Page 11: ... Main fuse box 5 Owner s tool kit 6 Rear shock absorber spring preload adjusting ring 10 9 8 7 6 page 6 29 7 Rear shock absorber damping force page 6 21 adjusting knob page 3 13 page 6 38 8 Helmet holder page 3 10 page 6 38 9 Shift pedal page 3 5 page 6 l I0 Starter choke lever Page 3 8 page 3 13 2 1 ...

Page 12: ...er cylinder reservoir 15 Main switch 16 Radiator cap 17 Radiator 18 Engine oil filter cartridge 19 Engine oil level check window 20 Brake pedal 21 Rear brake fluid reservoir 20 19 18 page 3 6 page 6 35 page 6 16 page 6 29 page 3 1 page 6 18 page 6 18 page 6 12 page 6 11 page 3 6 page 6 29 2 2 ...

Page 13: ... Clutch lever 2 Left handlebar switches 3 Speedometer unit 4 Right handlebar switches 5 Brake lever 6 Throttle grip 7 Tachometer 8 Coolant temperature gauge 8 7 6 page 3 5 page 3 3 page 3 2 page 3 4 page 3 5 page 6 22 page 3 3 page 3 3 2 3 ...

Page 14: ...are on but all other electrical sys tems are off The key can be removed The key must be pushed in from the OFF position to be turned to P ECA00043 Do not use the parking position for an extended length of time other wise the battery may discharge 1 Neutral indicator light NEUTRAL 2 Turn signal indicator light TURN 3 Fuel level warning light FUEL 4 High beam indicator light HIGH BEAM 5 Oil level wa...

Page 15: ...ning light does not come on have a Yamaha dealer check the electrical circuit NOTE EAU00064 High beam indicator light HIGH BEAM This indicator light comes on when the high beam of the headlight is switched on 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 1 Tripmeter reset knob 2 ...

Page 16: ...olant 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 47 for further instructions EC000002 Do not operate the engine if it is overheated 1 Dimmer switch LIGHTS 2 Turn signal switch TURN 3 Horn switch HORN Handlebar switches Dimmer switch LIGHTS Set the switch to HI for th...

Page 17: ...e stop switch ENGINE STOP cancel while you are stopped at an in Set this switch to OFF to stop the en tersection gine in case of an emergency such as when the motorcycle overturns or when the throttle cable is stuck 3 0 Horn switch HORN Press this switch to sound the horn EAU01653 Fuel reserve switch FUEL During normal operation this switch should be kept in the ON position If the fuel warning lig...

Page 18: ...er is equipped with a clutch switch which is part of the igni tion circuit cut off system See page 3 17 for an explanation of the ignition circuit cut off system Shift pedal EAU00157 The shift pedal is located on the left side of the engine and is used in com bination with the clutch lever when shifting the gears of the 5 speed con stant mesh transmission equipped on this motorcycle 1 Brake lever ...

Page 19: ...1 4 turn clockwise The The brake pedal is on the right side of lock will be released and the fuel the motorcycle To apply the rear To remove the fuel tank cap brake press down on the brake pedal 1 Push the levers on the left and tank cap can be opened right side of the rider seat backrest as shown and slide the rider seat backrest forward 3 6 ...

Page 20: ... the bottom of the filler tube as shown in the illustra tion EW000130 l Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands l Avoid spilling fuel on the hot engine EAU00185 Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU00189 Recommended fuel UNLEADED FUEL Fuel tank capacity Tota...

Page 21: ...l can be used if the ethanol con tent does not exceed 10 Gasohol containing methanol is not recom mended by Yamaha because it can cause damage to the fuel system or ve hicle performance problems 1 Starter choke lever 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 th...

Page 22: ... key 1 8 turn clockwise 4 Check that 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 key 2 Push the key in turn it 1 81 8 turn counterclockwise so that it moves out and then release it 3 Remove the key and then close the lock cover 1 Lever x 2 Rider seat EAU03413 To remove the rider seat 1 R...

Page 23: ...ighten the bolts and screws NOTE Make sure that the seat is properly se cured before riding 3 Return the rider seat backrest to the original position 1 Helmet holder 2 Open 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 Never ride with a helmet ...

Page 24: ...rstand NOTE When checking and adjusting the air pressure there should be no weight on the front end of the motorcycle 2 Remove the air valve cap from each fork leg 1 Air pressure gauge 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 ...

Page 25: ... left and right fork legs otherwise poor handling and loss of stability may result 5 Securely install the air valve caps 1 Shock absorber assembly x 2 Adjusting the shock absorber assemblies Both shock absorber assemblies are equipped with a spring preload adjust ing ring and a damping force adjusting knob EC00001 5 Never attempt to turn an adjusting mechanism beyond the maximum or minimum setting...

Page 26: ...a To de crease the spring preload and thereby soften the suspension turn the adjust ing ring on each shock absorber as sembly in direction b 1 Damping force adjusting knob 2 Position indicator Damping force To increase the damping force and thereby harden the damping turn the adjusting knob on each shock absorber assembly in direction a To decrease the damping force and thereby soften the damping ...

Page 27: ...INSTRUMENT AND CONTROL FUNCTIONS Damping force Minimum soft 1 Standard 1 Maximum hard 4 3 14 ...

Page 28: ...ion Rider only With passenger or with accessories and equipment Front fork adjustment Spring preload air pressure 40 60 kPa 0 4 0 6 kgf cm 5 7 8 5 psi 40 100 kPa 0 4 l 0 kgf cm 5 7 14 psi 40 100 kPa 0 4 l 0 kgf cm kgf c 5 7 14 psi Shock absorber assembly adjustment Spring preload Damping force l 2 l 2 3 5 2 4 With passenger accessories and equipment 5 4 EC000015 Never attempt to turn an adjusting ...

Page 29: ...histicated adjust ment Adjustment should be left to a Yamaha dealer who has the profes sional knowledge and experience to do so EC000025 The V Boost was set at the Yamaha factory after many tests If the set tings are changed by someone with out sufficient technical knowledge poor engine performance and dam age may result If the V Boost does not operate ask a Yamaha dealer to inspect it 3 16 ...

Page 30: ...fulfilling the responsibility 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 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...

Page 31: ...otorcycle should not be ridden until 1 1YES I With the engine still running 6 Move the sidestand up 7 Keep the clutch lever pulled 8 Shift the transmission into gear 9 Move the sidestand down Does the engine stall checked by a Yamaha dealer The sidestand switch may be defective The motorcycle should not be ridden until After the engine has stalled 10 Move the sidestand up 11 Keep the clutch lever ...

Page 32: ...e l Fill with DOT 4 brake fluid if necessary 6 27 6 30 Clutch l Check operation fluid level and for fluid leakage l Fill with DOT 4 brake fluid if necessary 6 26 6 29 Throttle grip and housing l Check operation Lubricate if necessary 6 22 6 31 Engine oil l Check oil level l Add oil if necessary 6 l 1 6 14 Coolant l Check coolant level l Add coolant if necessary 6 16 6 20 Final gear oil l Check veh...

Page 33: ...tery l Check operation l Check fluid level l Add distilled water if necessary 6 35 6 37 NOTE Pre operation checks should be made each time the motorcycle is used Such an inspection can be accomplished in a very short time and the added safety it assures is more than worth the time involved EWA00033 If any item in the Pre operation check list is not working properly have it inspected and repaired b...

Page 34: ...r resulting in a possible loss of control l Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer l Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result EAUO1164 Starting and warming up a cold engine In order for the ignition circuit cut off system t...

Page 35: ...tch is pushed and they should go off when the start switch is re leased If the oil level warning light flick ers or remains on after starting immediately stop the engine and then check the engine oil level and the vehicle for oil leak age If necessary add engine oil and then check the warning light again If the warning light does not come on when push ing the start switch or if it does 5 2 not go ...

Page 36: ...NANCE PROPER PERIODIC MAINTENANCE OF YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAINTENANCE SERVICES RELAT ED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOWING PERIODIC MAINTE NANCE CHARTS THE SERVICES RELATED TO EMISSIONS CON ...

Page 37: ...or repairs How ever additional tools such as a torque wrench may be necessary to perform certain maintenance work correctly EW000063 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 NOTE If you do not have the tools or experi ence required for a particular job have a Yamaha dealer perfor...

Page 38: ... or or or 1 month 6 months 12 months 18 months 24 months 30 months Every 30 000 mi 42 000 km or 42 months 4 Replace 4 Replace 4 Crankcase l Check ventilation hose for cracks or d a m a g e d d 4 4 4 ventilation system l Replace if necessary l Check fuel hoses for cracks or Fuel line d a m a g e i 4 d 4 4 l Replace if necessary l Replace initial 20 000 mi 31 000 km Fuel filter or 30 months and ther...

Page 39: ... 000 km 13 000 km 19 000 km 25 000 km 31 000 km Evaporative 9 emission control system For California only l Check control system for damage l Replace if necessary or or or or or or 1 month 6 months 12 months 18 months 24 months 30 months 4 4 Since these items require special tools data and technical skills have a Yamaha dealer perform the service 6 4 ...

Page 40: ...sed air 4 4 4 4 4 l Replace if necessary l Check hose for cracks or damage 4 4 4 4 4 4 l Cooling system l Replace if necessary l Replace coolant every Ethylene glycol 24 months antifreeze coolant Replace l Adjust free play 5 Brake system l Replace pads if li 4 4 4 4 4 necessary l Check operation and 6 Clutch fluid leakage See NOTE page 6 7 4 i 4 4 4 d l Correct if necessary l Check oil level and l...

Page 41: ... all purpose grease 4 4 4 4 4 lightly l Lubricate l Apply lithium soap Lithium soap based 1 Brake pedal and shift pedal shaft based grease grease 4 4 4 4 4 all purpose grease all purpose grease lightly l Check operation and lubricate 2 l Center sidestand l Apply lithium soap Lithium soap based pivots based grease grease 4 4 4 4 4 all purpose grease all purpose grease lightly 3 l Front fork l Check...

Page 42: ...igher than 20 000 mi 31 000 km or 30 months follow the maintenance require ments listed in the maintenance chart under the 4 000 mi 7 000 km or 6 month interval EAU03056 NOTE l The air filter needs more frequent service if you are riding in unusually wet or dusty areas l Hydraulic brake and clutch systems l After disassembling the master cylinder caliper cylinder or clutch release cylinder always ...

Page 43: ...he key into the lock and cowlings and panels ing with the projections on the then turn it clockwise frame The cowlings and panels shown above 2 Pull the cowling off as shown 2 Push down on the rear of the cowl need to be removed to perform some of the maintenance jobs described in this chapter Refer to this section each time a cowling or panel needs to be re moved and installed ing until it locks ...

Page 44: ...the panel Remove the screws and then take the panel off To install the panel Place the panel in the original position and then install the screws 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 ...

Page 45: ... defec tive Do not attempt to diagnose such problems yourself Instead have a Yamaha dealer check the motorcycle 3 Check each spark plug for elec trode erosion and excessive car J bon or other deposits and replace Spark plug gap 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 Specified spark plug DPR...

Page 46: ...on l Check each hose and canister for cracks or damage Replace if damaged l Make sure the vent hose is not blocked Clean it if necessary EAU02938 Engine oil and oil filter cartridge The engine oil level should be checked before each ride In addition the oil must be changed and the oil filter car tridge replaced at the intervals speci fied in the periodic maintenance and lubrication chart To check ...

Page 47: ...rm it up for at the bottom right side of the several minutes and then turn it off crankcase 2 Place an oil pan under the engine NOTE The engine oil should be between the minimum and maximum level marks to collect the used oil 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level 1 Engine oil drain bolt 3 Remove the engine o...

Page 48: ...ring 1 Torque wrench 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge 6 Install the new oil filter cartridge and then tighten it to the specified torque with a torque wrench NOTE Make sure that the O ring is properly seated 7 Install the engine oil drain bolt and then tighten it to the specified torque Tightening torque Engine oil drain bolt 43 Nm 4 3 m kg 31 ft lb ...

Page 49: ... also or remains on immediately turn the lubricates the clutch do not engine off and have a Yamaha deal mix any chemical additives with er check the vehicle the oil or use oils of a higher grade than CD In addition do 10 Turn the engine off and then check the oil level and correct it if l Make sure that no foreign mate not use oils labeled ENERGY rial enters the crankcase CONSERVING II or higher n...

Page 50: ...r bolt and drain bolt to drain the oil from the final gear case 4 Install the final gear oil drain bolt and then tighten it to the specified torque Tightening torque Final gear oil drain bolt 23 Nm 2 3 m kg 17 ft lb 5 Add the specified amount of the recommended final gear oil and then install and tighten the oil filler bolt Recommended final gear oil Hypoid gear oil SAE 80 API GL4 or multigrade hy...

Page 51: ...6 8 for cowling removal and installa tion procedures NOTE l The coolant level must be checked on a cold engine since the level varies with engine temperature l 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 minimu...

Page 52: ...er check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced EW000067 NOTE EAU03417 The radiator fan is automatically To change the coolant switched on or off according to the coolant temperature in the radiator If the engine overheats see page 6 47 for further instructions 1 2 Place the motorcycle on a level surface and let the engi...

Page 53: ...he radiator cap EW000067 1 Coolant drain cock 2 Position indicator 1 Water pump drain bolt 6 Remove the water pump drain bolt 5 Turn the coolant drain cock to ON to drain the water pump housing Never attempt to remove the radia tor cap when the engine is hot 6 1 8 ...

Page 54: ...lant drain and replace them if necessary plugs to drain the coolant from the 12 engine Turn the coolant drain cock to OFF After the coolant is completely 13 drained thoroughly flush the cool ing system with clean tap water Install the water pump drain bolt 14 and then tighten it to the specified torque Pour the recommended coolant into the reservoir to the maximum level and then install the cap Po...

Page 55: ...ot be protected against frost and corrosion l If water has been added to the coolant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced 15 Install the radiator cap start the engine let it idle for several min utes and then turn it off 16 Remove the radiator cap to check the coolant level in the radiator If...

Page 56: ...crews I I 1 Air filter element I 3 Pull the air filter element out 4 Lightly tap the air filter element to remove most of the dust and dirt and then blow the remaining dirt out with compressed air as shown If the air filter element is damaged replace it 5 Insert the air filter element into the air filter case EC000062 l Make sure that the air filter ele ment is properly seated in the air filter ca...

Page 57: ...e free play Adjusting the throttle cable free play The throttle cable free play should measure 3 5 mm 0 12 0 20 in at the throttle grip Periodically check the throttle cable free play and if neces sary have a Yamaha dealer adjust it EAU00637 Adjusting the valve clearance The valve clearance changes with use resulting in improper air fuel mixture and or engine noise To prevent this from occurring t...

Page 58: ...0 kgf cm 33 psi 36 psi Maximum load 216 kg 476 lb VMX12 215 kg 474 lb VMX12C I I Total weight of rider passenger cargo and accessories EW000083 m Proper loading of your motorcycle is important for several characteris tics of your motorcycle such as handling braking performance and safety Do not carry loosely packed items that can shift Securely pack your heaviest items close to the center of the m...

Page 59: ...M C 74V Type G526BW K525 I MInImum tire tread depth front and rear 1 O mm 0 04 in I EAU00664 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 l Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds l Brand new tires can have a rela tively poor grip on certain r...

Page 60: ...the specified torques l Ride at moderate speeds after changing a tire since the tire sur face must first be broken in for it to develop its optimal characteris tics EAU00691 Accessories and replacement parts EW000096 This motorcycle is not designed to pull a trailer or to be attached to a sidecar The accessories or replace ment parts you choose for your motorcycle should be designed spe cifically ...

Page 61: ...ch lever free play is not needed However it is necessary to check the clutch fluid lev el and check the hydraulic system for leakage before each ride If the clutch lever free play does become exces sive and shifting becomes rough or clutch slippage occurs causing poor acceleration there may be air in the clutch system If there is air in the hy draulic system have a Yamaha dealer bleed the system b...

Page 62: ...stem 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 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rection 8 To decrease the brake lever free play turn ...

Page 63: ...e brake light switch as follows Turn the adjusting nut while holding the rear brake light switch in place To make the brake light come on earlier turn the adjusting nut in direction To make the brake light come on later turn the adjusting nut in direction 8 1 Wear indicator x 2 EAU00715 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals s...

Page 64: ... precautions l When checking the fluid level make sure that the top of the mas ter cylinder is level by turning the handlebars l Use only the recommended quali ty brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performance Clutch 1 Recommended brake fluid DOT 4 6 2 9 1 Panel B 2 Minimum level mark l Refill with the same type of brake fluid Mixing f...

Page 65: ...on have the oil seals of the brake master cylinder and caliper as well as the brake hose replaced at the intervals listed below or whenever EAU03297 Checking and lubricating the cables Yamaha dealer check or replace it 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 i...

Page 66: ... 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 Recommended lubricant Throttle cable Yamaha Chain and Cable Lube or engine oil SAE 10W 30 Throttle grip housi...

Page 67: ...ever pivots should be lu bricated if necessary Checking and lubricating the centerstand 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 EWOOOl14 If the centerstand or sidestand does not move up and down smoothly have a Yamaha dealer check or re pair it 6 32 ...

Page 68: ...specified in the periodic main tenance and lubrication chart To check the condition EW000115 X Ndy SUppOfi the IllOtOrCyCk SO TO Check the Operation that there is no danger of it falling 1 Place the motorcycle on a level over surface and hold it in an upright Check the inner tubes for scratches position damage and excessive oil leakage 2 While applying the front brake push down hard on the handle ...

Page 69: ...vals specified in the pe riodic maintenance and lubrication chart 1 Place a stand under the engine to raise the front wheel off the ground EWOOO115 m 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 6 34...

Page 70: ...ned battery will cor rode and discharge quickly The elec trolyte level battery lead 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 1 Maximum level mark 2 Minimum level mark To check the electrolyte level 1 Place the motorcycle on a level surface and hold it in an upright position NOTE Make ...

Page 71: ...gnition coil assembly x 2 4 Remove the rider seat See page 4 Bolt x 2 3 9 for rider seat removal and in stallation procedures 5 Disconnect the negative battery lead from the battery 6 Disconnect the positive battery lead and the starter motor lead from the starter motor relay 7 Remove the ignition coil assem blies by removing the bolts 8 Add distilled water to raise the electrolyte to the maximum ...

Page 72: ...hysician l EYES Flush with water for 15 minutes and seek prompt medical attention l 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 l KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN EC000100 Use only distilled water as tap water contains minerals that are ...

Page 73: ...ery fully charge it and then place it in a cool dry place 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 Fully charge the battery before in stallation 4 After installation make sure that the battery leads are properly con nected to the battery terminals and that the breather...

Page 74: ...ical circuit in question 2 Remove the blown fuse and then install a new fuse of the specified amperage 1 Headlight fuse 2 Signaling system fuse 3 Ignition fuse 4 Radiator fan fuse 5 Spare fuse x 2 Specified fuses Main fuse 30A Headlight fuse 15A Signaling system fuse 10A Radiator fan fuse 10A Ignition fuse 10A EC000103 Do not use a fuse of a higher amper age rating than recommended to avoid causin...

Page 75: ...ere fore keep flammable products away from a lit headlight 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 1 Do not touch this area EC000105 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 ...

Page 76: ... 3 Insert a new bulb into the socket push it in and then turn it clock wise until it stops 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it in and turning it counter clockwise 1 Turn signal light bulb 4 Install the lens by installing the screws EC000108 Do not overtighten the screws oth erwise the lens may break 6 41 ...

Page 77: ...eel 1 Place the motorcycle on the cen 4 Wheel axle 1 Install the speedometer gear unit terstand 2 Disconnect the speedometer ca into the wheel hub so that the pro ble from the front wheel jections mesh with the slots 3 Remove the brake caliper by re moving the bolts ECA00047 Do not pull the brake lever after the brake caliper has been removed otherwise the brake pads will be forced shut 4 Loosen t...

Page 78: ...iner on the fork leg 3 Insert the wheel axle 4 Take the motorcycle off the cen terstand so that the front wheel is on the ground 5 Install the brake calipers by install ing the bolts 58 Nm 5 8 m kg 42 ft lb Front wheel axle pinch bolt 20 Nm 2 0 m kg 14 ft lb Brake caliper bolt 40 Nm 4 0 m kg 29 ft lb 7 Connect the speedometer cable 8 Push down hard on the handlebar several times to check for prope...

Page 79: ...he axle nut 4 Disconnect the brake torque rod from the brake caliper bracket by removing the cotter pin the nut and the 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 Do not push the brake pedal after the wheel has been removed togeth ...

Page 80: ...kg 35 ft lb Rear wheel axle pinch bolt 16 Nm 1 6 m kg 11 ft lb 8 Install the brake torque rod cotter pin EW000124 between the brake pads before install ing the brake caliper onto the brake disc Always use a new cotter pin Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression...

Page 81: ... There is no compression Have a Yamaha dealer check the vehicle 3 Ignition Remove the spark plugs and check the electrodes Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicle Open the throttle halfway and operate the electric starter 1 The engine does not start Check the battery 4 Battery The engine turns over The battery is g...

Page 82: ...cape When the hiss ing sound has stopped press down on the cap while turning it counterclockwise and then remove the cap The coolant level is low Check the cooling system r for leakage There is Have a Yamaha dealer check leakage and repair the cooling system Wait until the engine has cooled Check the coolant level in the reservoir and radiator There is no leakage Add coolant See NOTE 4 I I The coo...

Page 83: ...ll caps and covers as well as all electrical couplers and connectors including the spark plug caps are tightly in stalled 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 l Avoid using strong acidic wheel cleaners especial...

Page 84: ...not leave any marks If the wind shield is scratched use a quali ty plastic polishing compound after washing After normal use Remove dirt with warm water a mild detergent and a soft clean sponge and then rinse thoroughly with clean water Use a toothbrush or bottlebrush for hard to reach areas Stubborn dirt and insects will come off more easily if the area is covered with a wet cloth for a few minut...

Page 85: ...ed by stones etc Wax all painted surfaces Let the motorcycle dry completely before storing or covering it EWA00031 ECA00013 l Make sure that there is no oil or wax on the brakes or tires l 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 br...

Page 86: ... the drain bolts this will prevent fuel deposits from building up Pour the drained fuel into the fuel tank Fill up the fuel tank and add fuel stabilizer if available to prevent the fuel tank from rusting and the fuel from deteriorating Perform the following steps to pro d e Remove the spark plug caps and spark plugs Pour a teaspoonful of engine oil into each spark plug bore Install the spark plug ...

Page 87: ...at both of its wheels are off the ground Alterna tively turn the wheels a little every month in order to prevent the tires from becoming degraded in one spot Cover the muffler outlets with plas tic bags to prevent moisture from entering them 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 ...

Page 88: ...98 cm 76 x 66 mm 3 0 x 2 6 in 10 5 1 Electric starter Wet sump 8 l Type 0 10 30 50 70 90 110 130 F i i I i YAMALUBE 4 10W 30 i i jor SAE 10W 30 j i YAMALUBE 4 20W 40 or SAE 20W 40 20 lh i lb 2cl 3cI 4b 5 o C Recommended engine oil classification API Service SE SF SG type or higher Be sure to use motor oils that do not contain anti friction modifiers Passenger car motor oils often labeled Energy Co...

Page 89: ...US qt 3 05 L 2 68 Imp qt 3 22 US qt Dry type element Unleaded fuel 15 L 3 3 Imp gal 4 0 US gal 3 L 0 7 Imp gal 0 8 US gal MIKUNI BDS35 x 4 DPR8EA 9 NGK or X24EPR U9 DENS0 0 8 0 9 mm 0 03 0 04 in Wet multiple disc Spur gear 1 775 Shaft drive 2 851 Constant mesh 5 speed 8 2 Operation Gear ratio 1 st 2 n d 3 r d 4 t h 5th Chassis Frame type Caster angle Trail Tires Front Type Size Manufacturer model ...

Page 90: ...s Wheels Front Type Cast wheel Size 18 x MT2 15 Rear Type Cast wheel Size 15M C x MT 3 50 Brakes Front Type Dual disc brake Rear Operation Fluid Type Operation Fluid Suspension Front Rear Spring shock absorber Front Rear Wheel travel Front Rear Electrical system Ignition system Charging system Type Standard output Battery M o d e l Voltage capacity Headlight type Right hand D O T 4 Single disc bra...

Page 91: ...or light High beam indicator light Turn signal indicator light Fuel level warning light Oil level warning light Fuses Main fuse Headlight fuse Signaling system fuse Radiator fan fuse Ignition fuse 12 V 60 55 W x 1 12 V 8 27 W x 2 12 V 27 8 W x 2 12 V 27 W x 2 14 V 3 W x 2 14 V 3 W x 1 14 V 3 W x 1 14 V 3 W x 1 14 V 3 W x 1 14 V 3 W x 1 30A 15A 10A 10A 10A 8 4 ...

Page 92: ...NFORMATION L w w L If 1 1 Key identification number 1 Vehicle identification number EAU01042 Key identification number Vehicle identification number The key identification number is The vehicle identification number is stamped into the key Record this num stamped into the steering head pipe ber in the space provided and use it for Record this number in the space pro reference when ordering a new k...

Page 93: ...abel The model label is affixed under cowl ing A See page 6 8 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 9 2 ...

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