Yamaha VMAX VMX12R Owner'S Manual Download Page 82

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-31

EAU04034

Checking and lubricating the
throttle grip and cable

The operation of the throttle grip should
be checked before each ride. In addi-
tion, the cable should be lubricated or
replaced at the intervals specified in
the periodic maintenance chart.

EAU03370

Checking and lubricating the
brake and shift pedals

The operation of the brake and shift
pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease
(all-purpose grease)

E_5GK.book Page 31 Friday, May 31, 2002 10:59 AM

Summary of Contents for VMAX VMX12R

Page 1: ...5GK 28199 13 LIT 11626 16 20 VMX12R VMX12RC OWNER S MANUAL ...

Page 2: ...EAU03438 ...

Page 3: ...otorcycle 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 motorcycle To maintain these hi...

Page 4: ...st 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 inform...

Page 5: ...MPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MOTORCYCLE E_5GK book Page 2 Friday May 31 2002 10 59 AM ...

Page 6: ...AL 2002 by Yamaha Motor Corporation U S A 1st edition April 2002 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 16 20 E_5GK book Page 3 Friday May 31 2002 10 59 AM ...

Page 7: ... 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_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 8: ... INFORMATION 1 Safe riding 1 1 Protective apparel 1 3 Modifications 1 3 Loading and accessories 1 3 Gasoline and exhaust gas 1 5 Location of important labels 1 7 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 9: ...CHANICAL 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 see the motorcycl...

Page 10: ...cornering 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 feet on the operator...

Page 11: ...eration 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 may also make your mo...

Page 12: ...hese items in cluding such cargo 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 non Yamaha accessorie...

Page 13: ...lity therefore such accessories are not recommended 2 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 Take care not to sp...

Page 14: ... 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 spills on your ski...

Page 15: ...SAFETY INFORMATION 1 1 7 EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle E_5GK book Page 7 Friday May 31 2002 10 59 AM ...

Page 16: ...e set as follows 90 kg 198 lbs maximum load 225 kPa 2 25 kgf cm2 33 psi FRONT 250 kPa 2 50 kgf cm2 36 psi REAR Up to 90 kg 198 lbs load 225 kPa 2 25 kgf cm2 33 psi FRONT 225 kPa 2 25 kgf cm2 33 psi REAR TIRE INFORMATION WARNING PASS LEAD WIRES THROUGH HOLE 3JP 2415H A0 as shown A short circuit could result from improper routing This could cause the engine to stop running and lights to fail which c...

Page 17: ...DESCRIPTION 2 Left view 2 1 Right view 2 2 Controls and instruments 2 3 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 18: ...ge 6 39 4 Main fuse box page 6 39 5 Owner s tool kit page 6 1 6 Shock absorber assembly spring preload adjusting ring page 3 13 7 Shock absorber assembly damping force adjusting knob page 3 13 8 Helmet holder page 3 10 9 Shift pedal page 3 5 10 Starter choke lever page 3 8 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 19: ... 14 Front brake fluid reservoir page 6 29 15 Main switch page 3 1 16 Radiator cap page 6 18 17 Radiator page 6 18 18 Engine oil filter cartridge page 6 13 19 Engine oil level check window page 6 12 20 Brake pedal page 3 6 21 Rear brake fluid reservoir page 6 29 E_5GK book Page 2 Friday May 31 2002 10 59 AM ...

Page 20: ...age 3 5 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Right handlebar switches page 3 4 5 Brake lever page 3 5 6 Throttle grip page 6 22 7 Tachometer page 3 3 8 Coolant temperature gauge page 3 3 E_5GK book Page 3 Friday May 31 2002 10 59 AM ...

Page 21: ... Shift pedal 3 5 Brake lever 3 5 Brake pedal 3 6 Fuel tank cap 3 6 Fuel 3 7 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 V Boost 3 16 Sidestand 3 17 Ignition circuit cut off system 3 17 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 22: ...re off The key can be removed The key must be pushed in from the OFF position to 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 EAU00062 Neutral indicator light NEUTRAL This indicator light comes on when the transmission is in the neutral position EAU00059 Turn signal indi...

Page 23: ...ow The electrical circuit of the warning light can be checked according to the fol lowing procedure 1 Set the engine stop switch to RUN and turn the key to ON 2 Shift the transmission into the neu tral position or pull the clutch lever 3 Push the start switch If the warn ing light does not come on have a Yamaha dealer check the electri cal circuit NOTE Even if the oil level is sufficient the warni...

Page 24: ...r enters the red zone stop the motorcycle and let the engine cool See page 6 48 for further instructions EC000002 CAUTION Do not operate the engine if it is overheated EAU00118 Handlebar switches EAU00122 Dimmer switch LIGHTS Set the switch to HI for the high beam and to LO for the low beam EAU01189 Turn signal switch TURN To signal a right hand turn push this switch to the right To signal a left ...

Page 25: ... STOP Set this switch to RUN before starting the engine Set this switch to OFF to stop the engine in case of an emergen cy such as when the motorcycle over turns or when the throttle cable is stuck EAU01653 Fuel reserve switch FUEL During normal operation this switch should be kept in the ON position If the fuel warning light comes on while riding set the switch to RES refuel as soon as possible a...

Page 26: ... of the igni tion circuit cut off system See page 3 17 for an explanation of the ignition circuit cut off system EAU00157 Shift pedal 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 EAU00158 Brake lever The brake lever is located at the right ha...

Page 27: ...68 Fuel tank cap To remove the fuel tank cap 1 Push the levers on the left and right side of the rider seat backrest as shown and slide the rider seat backrest forward 2 Insert the key into the lock and then turn it 1 4 turn clockwise The lock will be released and the fuel tank cap can be removed 1 Brake pedal 1 Lever 2 1 Unlock E_5GK book Page 6 Friday May 31 2002 10 59 AM ...

Page 28: ...ere is sufficient fuel in the tank Fill the fuel tank to the bottom of the filler tube as shown EW000130 WARNING _ Do not overfill the fuel tank oth erwise it may overflow when the fuel warms up and expands Avoid spilling fuel on the hot engine _ EAU00185 CAUTION Immediately wipe off spilled fuel with a clean dry soft cloth since fuel may deteriorate painted surfac es or plastic parts EAU04265 ECA...

Page 29: ... of gasohol gaso hol containing ethanol and that contain ing methanol Gasohol containing ethanol 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 EAU00211 Starter choke lever Starting a cold engine requires a richer air fuel mixture which is supplied by th...

Page 30: ...hat 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 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 pushing the levers on the le...

Page 31: ...e cured 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 contro...

Page 32: ...e air 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...

Page 33: ...ock 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 so...

Page 34: ...sorber 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 ...

Page 35: ...INSTRUMENT AND CONTROL FUNCTIONS 3 14 3 Damping force Minimum soft 1 Standard 1 Maximum hard 4 E_5GK book Page 14 Friday May 31 2002 10 59 AM ...

Page 36: ...ttempt 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 kgf cm2 5 7 8 5 psi 1 2 1 2 With passenger or with accessories and equipment 40 100 kPa 0 4 1 0 kgf cm2 5 7 14 psi 3 5 2 4 With passenger accessories and equipment 4...

Page 37: ...and experience to do so EC000025 CAUTION 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 The V Boost operation can be heard when the main switch is turned on EC000026 CAUTION If the V Boost does not operate ask a Yamaha dealer to inspect it E_5GK book Page 16 Fr...

Page 38: ...ng 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 EAU03741 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 gear and the s...

Page 39: ...ep the 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 ...

Page 40: ...PRE OPERATION CHECKS 4 Pre operation check list 4 1 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 41: ...evel in engine If necessary add recommended oil to specified level Check vehicle for oil leakage 6 11 6 12 Final gear oil Check vehicle for oil leakage 6 15 Coolant Check coolant level in reservoir If necessary add recommended coolant to specified level Check cooling system for leakage 6 16 6 17 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever fre...

Page 42: ... Correct if necessary 6 23 6 25 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 31 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 32 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 32 Chassis fasteners Make sure that all nuts bolts and screws ...

Page 43: ...ection can be accomplished in a very short time and the added safety it assures is more than worth the time involved _ EWA00033 WARNING _ If any item in the Pre operation check list is not working properly have it inspected and repaired before operating the motorcycle _ E_5GK book Page 3 Friday May 31 2002 10 59 AM ...

Page 44: ...OPERATION AND IMPORTANT RIDING POINTS 5 Starting and warming up a cold engine 5 1 Starting a warm engine 5 3 Shifting 5 3 Engine break in 5 5 Parking 5 6 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 45: ... of control EAU00376 CAUTION Make sure not to store personal items near the air cleaner in take otherwise air intake will be blocked and performance will suffer Make sure not to put anything near the battery and its termi nals otherwise electrical failure and acid corrosion may result EAU04700 Starting and warming up a cold engine In order for the ignition circuit cut off system to enable starting...

Page 46: ...ushed 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 not go off after st...

Page 47: ...35 seconds with the starter choke turned on then about 2 5 min utes with the starter choke in the half way position _ EAU01258 Starting a warm engine Follow the same procedure as for start ing a cold engine with the exception that the starter choke is not required when the engine is warm EAU00423 Shifting Shifting gears lets you control the amount of engine power available for starting off acceler...

Page 48: ...clutch lever slowly 4 At the recommended shift points shown in the table on page 5 5 close the throttle and at the same time quickly pull the clutch lever in 5 Shift the transmission into second gear Make sure not to shift the transmission into the neutral posi tion 6 Open the throttle part way and gradually release the clutch lever 7 Follow the same procedure when shifting to the next higher gear...

Page 49: ...ny condition that might result in engine overheating must be avoided EAU04032 0 1 000 km 0 600 mi Avoid prolonged operation above 4 500 r min 1 000 1 600 km 600 1 000 mi Avoid prolonged operation above 5 500 r min EC000056 CAUTION _ After 1 000 km 600 mi of operation the engine oil and final gear oil must be changed and the oil filter car tridge replaced _ 1 600 km 1 000 mi and beyond The vehicle ...

Page 50: ...ve the key from the main switch EW000058 WARNING Since the engine and exhaust system can become very hot park in a place where pedestri ans or children are not likely to touch them Do not park on a slope or on soft ground otherwise the motorcycle may overturn E_5GK book Page 6 Friday May 31 2002 10 59 AM ...

Page 51: ...he brake pedal position 6 27 Adjusting the rear brake light switch 6 28 Checking the front and rear brake pads 6 28 Checking the brake and clutch fluid levels 6 29 Changing the brake and clutch fluids 6 30 Checking and lubricating the cables 6 30 Checking and lubricating the throttle grip and cable 6 31 Checking and lubricating the brake and shift pedals 6 31 Checking and lubricating the brake and...

Page 52: ...E 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 TROL...

Page 53: ...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 _ EW000062 WARNING _ Modifications not approved by Yamaha may cause loss of perfor mance excessive emissions and render the vehicle unsafe for use Consult a Yamaha dealer before at tempting an...

Page 54: ...m or 42 months 2 Spark plugs Check condition Adjust gap and clean Replace every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventilation system Check ventilation hose for cracks or damage Replace if necessary 4 Fuel line Check fuel hoses for cracks or damage Replace if necessary 5 Fuel filter Replace every 20 000 mi 31 000 km or 30 months Replace 6 Exhaust system Check for leakage T...

Page 55: ...ission control system For California only Check control system for damage Replace if necessary No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1 000 km or 1 month 4 000mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months E_5GK book Page 4 Friday May 31 2002 10 59 AM ...

Page 56: ...ridge Replace 3 Air filter element Clean with compressed air Replace if necessary 4 Cooling system Check hose for cracks or damage replace if necessary Replace every 16 000 mi 25 000 km or 24 months High quality ethylene glycol antifreeze containg corrosin inhibitors for aluminum engine Replace 5 Brake system Adjust free play Replace pads if necessary 6 Clutch Check operation and fluid leakage See...

Page 57: ...p based grease all purpose grease lightly Lithium soap based grease all purpose grease 12 Center sidestand pivots Check operation and lubricate Apply lithium soap based grease all purpose grease lightly Lithium soap based grease all purpose grease 13 Front fork Check operation and leakage 14 Steering bearings Check bearing assembly for looseness Moderately repack every 16 000 mi 25 000 km or 24 mo...

Page 58: ... check the brake and clutch fluid levels and fill the reservoirs as required Replace the oil seals on the inner parts of the brake or clutch master cylinders caliper cylinders and clutch release cylinder every two years Replace the brake and clutch hoses every four years or if cracked or damaged _ 15 Wheel bearings Check bearings for smooth rotation 16 Battery Check specific gravity and breather p...

Page 59: ...nel needs to be removed 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...

Page 60: ...nel 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 c...

Page 61: ... 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 then w...

Page 62: ...ace if damaged Make sure the vent hose is not blocked Clean it if necessary EAU04623 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 the engine oil level 1 Place the motorcycle on the cen tersta...

Page 63: ... to raise it to the correct level To change the engine oil with or without oil filter cartridge replace ment 1 Start the engine warm it up for several minutes and then turn it off 2 Place an oil pan under the engine to collect 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 _ ...

Page 64: ...ng is properly seated _ 6 Install the new oil filter cartridge with an oil filter wrench and then tighten it to the specified torque with a torque wrench 7 Install the engine oil drain bolt and then tighten it to the specified torque 1 Oil filter cartridge 2 Oil filter wrench 1 O ring 1 Torque wrench Tightening torque Oil filter cartridge 17 Nm 1 7 m kgf 12 ft lbf Tightening torque Engine oil drai...

Page 65: ...everal 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 deal er check the vehicle _ 10 Turn t...

Page 66: ...he oil level should be at the brim of the filler hole _ 3 If the oil is below the brim of the fill er hole add sufficient oil of the rec ommended type to raise it to the correct level To change the final gear oil 1 Place an oil pan under the final gear case to collect the used oil 2 Remove the oil filler bolt and drain bolt to drain the oil from the final gear case 3 Install the final gear oil dra...

Page 67: ...ine 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 below the minimum level mark remove the coolant res...

Page 68: ...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 radia tor If the engine overheats see page 6 48 for further instructions _ EAU04865 To change the coolant ...

Page 69: ...er 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_5GK book Page 18 Friday May 31 2002 10 59 AM ...

Page 70: ...fied 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 ...

Page 71: ...in 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 Start the engine and then check ...

Page 72: ... 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 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 ...

Page 73: ...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 the valve clearance must be adjusted...

Page 74: ... carry loosely packed items that can shift Securely pack your heaviest items close to the center of the motorcycle and dis tribute the weight evenly from side to side Properly adjust the suspen sion for your load and check the condition and pressure of your tires NEVER OVERLOAD YOUR MOTOR CYCLE Make sure the total weight of the cargo rider passenger and accessories cowling saddlebags etc if approv...

Page 75: ...super high speeds Brand new tires can have a rela tively poor grip on certain road surfaces until they have been broken in Therefore it is ad visable before doing any high speed riding to ride conserva tively for approximately 100 km 60 mi after installing a new tire The tires must be warmed up before a high speed run Always adjust the tire air pres sure according to the operating conditions 1 Tir...

Page 76: ...or replacing a tire tighten the valve stem nut and locknut to the specified torques EAU00691 Accessories and replacement parts EW000098 WARNING 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 for this model and they must be securely mounted to main tain the inheren...

Page 77: ... 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 before operating th...

Page 78: ...ake 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 position ...

Page 79: ...he 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 is provided wi...

Page 80: ... reservoir is level 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 brake or clutch fluid reservoir diaphragm will lose its shape from the negative pressur...

Page 81: ...e brake and clutch hoses replaced at the intervals listed below or whenever they are damaged or leaking Oil seals Replace every two years Brake and clutch hoses Replace every four years EAU03297 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 ...

Page 82: ...hould be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU03370 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all purpose grease E_5GK book Page 31 Friday May 31 2002 10 59 ...

Page 83: ...and 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 ...

Page 84: ...tion EW000115 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 bound...

Page 85: ... pe 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_5GK book Page 34 ...

Page 86: ...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 To check the electrolyte level 1 Place the motorcycle on the cen terstand NOTE _ Make sure that the motorcycle is posi tioned straight up when checking the electrolyte level _ 2 Check the electrolyte level in the battery NOTE...

Page 87: ...ry lead from the battery 6 Disconnect the positive battery lead and the starter motor lead from the starter motor relay 7 Disconnect the couplers shown 8 Remove the ignition coil assem blies by removing the bolts 9 Add distilled water to raise the electrolyte to the maximum level mark 1 Starter moter lead black 2 Positive battery lead red 3 Negative battery lead 1 Ignition coil assembly 2 2 Bolt 2...

Page 88: ...r 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 battery ...

Page 89: ...th 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...

Page 90: ...then 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 M...

Page 91: ...he bulb until it has cooled down _ 4 Place a new headlight 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 bulb using ...

Page 92: ...tive 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_5GK book Page 41 Friday May 31 2002 10 59 AM ...

Page 93: ... Remove the brake calipers 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 EAU04360 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the...

Page 94: ...iscs _ 5 Install the brake hose holders by installing the bolts 6 Take the motorcycle off the cen terstand so that the front wheel is on the ground 7 Tighten the wheel axle then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques 8 Connect the speedometer cable 9 Push down hard on the handlebar several times to check for proper fork operation 1 Retainer Tightening ...

Page 95: ...r _ 1 Remove the axle nut and then loosen the rear wheel axle pinch bolt 2 Place the motorcycle on the cen terstand 3 Remove the brake caliper by re moving the bolts 4 Disconnect the brake torque rod from the brake caliper bracket by removing the cotter pin the nut and the bolt 1 Axle nut 1 Rear wheel axle pinch bolt 1 Nut 2 Cotter pin 3 Brake torque rod 4 Bolt 3 5 Spacer 6 Brake caliper bracket E...

Page 96: ...ake caliper by install ing the bolts NOTE _ Make sure that there is enough space between the brake pads before install ing the brake caliper onto the brake disc _ 4 Connect the brake torque rod to the brake caliper bracket by in stalling the bolt and the nut 5 Install the axle nut and then slight ly tighten it 6 Take the motorcycle off the cen terstand so that the rear wheel is on the ground 7 Tig...

Page 97: ...loss of power The following 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 par...

Page 98: ...ck the 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 ...

Page 99: ...he hiss 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 Chec...

Page 100: ...E_5GK book Page 49 Friday May 31 2002 10 59 AM ...

Page 101: ...MOTORCYCLE CARE AND STORAGE 7 Care 7 1 Storage 7 4 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 102: ... well as all electrical couplers and connectors including the spark plug caps are tightly in 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 o...

Page 103: ...ind 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 minutes before cleaning After rid...

Page 104: ...l painted 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 ...

Page 105: ...revent 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 b...

Page 106: ...ry 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 30 F or more than 30 C 90 F For more informa tion on storing the b...

Page 107: ...SPECIFICATIONS 8 Specifications 8 1 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 108: ...ctric 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 2 82 Imp qt 3 38 US qt With oil filter cartridge replacement 3 4 L 2 99 Imp qt 3 59 US qt Total amount dry engine 4 L 3 52 Imp qt 4 23 US qt 0 10 30 50 70 90 110 130 F YAMALUBE 4 20W 40 or SAE 20W 40 20 10 0 10 20 30 ...

Page 109: ...4EPR U9 DENSO Gap 0 8 0 9 mm 0 03 0 04 in Clutch type Wet multiple disc Transmission Primary reduction system Spur gear Primary reduction ratio 1 775 Secondary reduction system Shaft drive Secondary reduction ratio 2 851 Transmission type Constant mesh 5 speed Operation Left foot Gear ratio 1st 2 529 2nd 1 772 3rd 1 347 4th 1 076 5th 0 928 Chassis Frame type Double cradle Caster angle 29 Trail 119...

Page 110: ...ont Type Cast wheel 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 5 5 in Rear 100 mm 3 9 in Electrical sys...

Page 111: ...t 12 V 27 W 2 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_5GK book Page 4 Friday May 31 2002 10 59 AM ...

Page 112: ...e identification number 9 1 Model label 9 2 Reporting safety defects 9 3 Motorcycle noise regulation 9 4 Maintenance record 9 5 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 9 7 YAMAHA EXTENDED SERVICE Y E S 9 9 E_5GK book Page 1 Friday May 31 2002 10 59 AM ...

Page 113: ...CA 01E 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 ...

Page 114: ...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 1 Model label E_5GK book Page 2 Friday May 31 2002 10 59 AM ...

Page 115: ...nvestigation 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 individual problems between you your dealer or Yamaha Motor Corporation 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 Tr...

Page 116: ...le 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 rendered inoperative by any person AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW These acts include tampering with the following systems i e modification removal etc CL ...

Page 117: ...is printed only as a reminder that maintenance work is required It is not acceptable proof of maintenance work CL 04E Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1 000 km or 1 month 4 000 mi 7 000 km or 6 months 8 000 mi 13 000 km or 12 months 12 000 mi 19 000 km or 18 months 16 000 mi 25 000 km or 24 months 20 000 mi 31 000 km or 30 months 24 000 ...

Page 118: ...m or 42 months 32 000 mi 49 000 km or 48 months 36 000 mi 55 000 km or 54 months 40 000 mi 61 000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks E_5GK book Page 6 Friday May 31 2002 10 59 AM ...

Page 119: ...CONSUMER INFORMATION 9 7 9 EAU02918 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY E_5GK book Page 7 Friday May 31 2002 10 59 AM ...

Page 120: ...CONSUMER INFORMATION 9 8 9 E_5GK book Page 8 Friday May 31 2002 10 59 AM ...

Page 121: ...CONSUMER INFORMATION 9 9 9 EAU01063 YAMAHA EXTENDED SERVICE Y E S E_5GK book Page 9 Friday May 31 2002 10 59 AM ...

Page 122: ...CONSUMER INFORMATION 9 10 9 E_5GK book Page 10 Friday May 31 2002 10 59 AM ...

Page 123: ...h 3 4 F Final gear oil 6 15 Front fork adjusting 3 11 Front fork checking 6 33 Fuel 3 7 Fuel level warning light 3 2 Fuel reserve switch 3 4 Fuel tank cap 3 6 Fuses replacing 6 39 H Handlebar switches 3 3 Headlight bulb replacing 6 40 Helmet holder 3 10 High beam indicator light 3 2 Horn switch 3 4 I Identification numbers 9 1 Ignition circuit cut off system 3 17 Indicator and warning lights 3 1 K...

Page 124: ...cable checking and lubricating 6 31 Tires 6 23 Tool kit 6 1 Troubleshooting 6 46 Troubleshooting charts 6 47 Turn signal indicator light 3 1 Turn signal light bulb or the tail brake light bulb replacing 6 41 Turn signal switch 3 3 V Valve clearance adjusting 6 22 V Boost 3 16 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 35 Wheel front 6 4...

Page 125: ...PRINTED IN JAPAN 2002 05 0 9 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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