Yamaha VMAX VMX12S Owner'S Manual Download Page 41 | Manualshive

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-2

6

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.

WARNING

EWA10340

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 any changes.

5GK14.book Page 2 Friday, April 11, 2003 1:07 PM

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Summary of Contents for VMAX VMX12S

Page 1: ...5GK 28199 14 LIT 11626 17 15 VMX12S OWNER S MANUAL ...

Page 2: ...EAU10041 5GK14 book Page 1 Friday April 11 2003 1 07 PM ...

Page 3: ...rcycle 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 emissions 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 high s...

Page 4: ...KLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED 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 RELIABILIT...

Page 5: ...ration U S A 1st edition April 2003 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 17 15 AFFIX DEALER LABEL HERE 5GK14 book Page 2 Friday April 11 2003 1 07 PM ...

Page 6: ... 6 1 Periodic maintenance chart for the emission control system 6 3 General maintenance and lubrication chart 6 4 Removing and installing the cowling and panels 6 8 Checking the spark plugs 6 9 Engine oil and oil filter cartridge 6 10 Final gear oil 6 13 Coolant 6 14 Cleaning the air filter element 6 17 Adjusting the carburetors 6 18 Adjusting the throttle cable free play 6 19 Adjusting the valve ...

Page 7: ...ront wheel 6 36 Rear wheel 6 37 Troubleshooting 6 39 Troubleshooting charts 6 40 MOTORCYCLE CARE AND STORAGE 7 1 Care 7 1 Storage 7 3 SPECIFICATIONS 8 1 CONSUMER INFORMATION 9 1 Identification numbers 9 1 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 ...

Page 8: ...dents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous appears to be very effective in reducing the chance of this type of accident Therefore Wear a brightly colored jacket Use extra caution when you are approaching and passing through intersections since in tersections are the most likely places for motorcycle accidents to occur Ride where other ...

Page 9: ...shield or goggles Wind in your unprotected eyes could contribute to an impairment of vision that could delay seeing a hazard The use of a jacket heavy boots trousers gloves etc is effective in preventing or reducing abrasions or lacerations Never wear loose fitting clothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident Never touch the engine or...

Page 10: ...ed under Load ing when mounting accessories Never install accessories or carry cargo that would impair the perfor mance of your motorcycle Care fully inspect the accessory before using it to make sure that it does not in any way reduce ground clearance or cornering clearance limit suspension travel steering travel or control operation or ob scure lights or reflectors Accessories fitted to the hand...

Page 11: ...te the following The engine and exhaust system may be hot therefore park the motorcycle in a place where pe destrians or children are not like ly to touch these hot areas Do not park the motorcycle on a slope or soft ground otherwise it may fall over Do not park the motorcycle near a flammable source e g a ker osene heater or near an open flame otherwise it could catch fire When transporting the m...

Page 12: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle 5GK14 book Page 5 Friday April 11 2003 1 07 PM ...

Page 13: ...SAFETY INFORMATION 1 6 1 1 3 2 4 5GK14 book Page 6 Friday April 11 2003 1 07 PM ...

Page 14: ...e 6 33 4 Main fuse box page 6 33 5 Owner s tool kit page 6 1 6 Shock absorber assembly spring preload adjusting ring page 3 11 7 Shock absorber assembly damping force adjusting knob page 3 11 8 Helmet holder page 3 10 9 Shift pedal page 3 5 10 Starter choke lever page 3 8 5GK14 book Page 1 Friday April 11 2003 1 07 PM ...

Page 15: ...e 6 14 4 Front brake fluid reservoir page 6 25 5 Main switch page 3 1 6 Radiator cap page 6 14 7 Radiator page 6 14 8 Engine oil filter cartridge page 6 10 9 Engine oil level check window page 6 10 10 Brake pedal page 3 6 11 Rear brake fluid reservoir page 6 25 5GK14 book Page 2 Friday April 11 2003 1 07 PM ...

Page 16: ...er page 3 5 2 Left handlebar switches page 3 3 3 Speedometer unit page 3 2 4 Right handlebar switches page 3 3 5 Brake lever page 3 5 6 Throttle grip page 6 19 7 Tachometer page 3 3 8 Coolant temperature gauge page 3 3 5GK14 book Page 3 Friday April 11 2003 1 07 PM ...

Page 17: ...s tems are off The key can be removed The key must be pushed in from the OFF position to be turned to P CAUTION ECA11020 Do not use the parking position for an extended length of time other wise the battery may discharge EAU11000 Indicator and warning lights EAU11040 Turn signal indicator light TURN This indicator light flashes when the turn signal switch is pushed to the left or right EAU11070 Ne...

Page 18: ...on when the fuel level drops below approximately 3 0 L 0 79 us gal 0 66 imp gal When this occurs set the fuel reserve switch to the RES position and refuel as soon as possible The electrical circuit of the warning light can be checked according to the follow ing 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 clut...

Page 19: ...re 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 vehicle and let the en gine cool See page 6 40 CAUTION ECA10020 Do not operate the engine if it is overheated EAU12341 Handlebar switches Left Right 1 Tachometer 2 Tachometer red zone 1 Coolant temperature gauge 2 Coolant temperature gauge red zone 1 D...

Page 20: ...hat the turn signal lights will not self cancel while you are stopped at an intersec tion EAU12510 Horn switch HORN Press this switch to sound the horn EAU12650 Engine stop switch ENGINE 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 vehicle overturns or when the throttle cable is stuck EAU12690 Start switc...

Page 21: ...a clutch switch which is part of the igni tion circuit cut off system See page 3 14 EAU12870 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 EAU12890 Brake lever The brake lever is located at the right handlebar grip To apply the fro...

Page 22: ...l tank cap can be removed To install the fuel tank cap 1 Insert the fuel tank cap into the tank opening with the key inserted in the lock and with the mark on the cap facing forward 2 Turn the key counterclockwise to the original position and then re move 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 additi...

Page 23: ...a engine has been de signed to use regular unleaded gaso line with a pump octane number R M 2 of 86 or higher or a research octane number of 91 or higher If knocking or pinging occurs use a gasoline of a different brand or premi um unleaded fuel Use of unleaded fuel will extend spark plug life and reduce maintenance costs Gasohol There are two types of gasohol gaso hol containing ethanol and that ...

Page 24: ...pen the steering lock cover and then insert the key 3 Turn the key 1 8 turn counterclock wise push it in while turning the handlebar slightly to the left and then turn the key 1 8 turn clock wise 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 key 2 Push the key in turn it 1 8 turn counterclo...

Page 25: ...en pull the rider seat off To install the rider seat 1 Insert the projection on the front of the rider seat into the seat holder as shown 2 Place the rider seat in the original position and then tighten 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 Opening lever 1 Bolt 2 Screw 1 Projection 2 Seat hol...

Page 26: ...justing the spring rate WARNING EWA10180 Always adjust both fork legs equal ly otherwise poor handling and loss of stability may result Adjust the spring rate as follows 1 Elevate the front wheel by placing the vehicle on the centerstand NOTE When checking and adjusting the air pressure there should be no weight on the front end of the vehicle 2 Remove the air valve cap from each fork leg 3 Check ...

Page 27: ...damping force adjusting knob CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings WARNING EWA10210 Always adjust both shock absorber assemblies equally otherwise poor handling and loss of stability may result Spring preload To increase the spring preload and thereby harden the suspension turn the adjusting ring on each shock ab sorber assembly in dir...

Page 28: ...ndling read and under stand the following information be fore handling the shock absorbers The manufacturer cannot be held re sponsible for property damage or personal injury that may result from improper handling Do not tamper with or attempt to open the gas cylinders Do not subject the shock ab sorbers to an open flame or oth er high heat sources otherwise they may explode due to exces sive gas ...

Page 29: ...the profes sional knowledge and experience to do so CAUTION ECA10170 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 CAUTION ECA10180 If the V Boost does not operate ask a Yamaha dealer to insp...

Page 30: ...the sidestand be fore starting off Therefore check this system regularly as described below and have a Yamaha dealer re pair it if it does not function proper ly EAU15321 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 sid...

Page 31: ...fter 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 system is OK The motorcycle can be ridden This check is most reliable if performed with a warmed up engine The neutral switch may be defective The motorcycle should not be ridden until checked by a Yamaha dealer The sidestand switch may be defective The motorcycle...

Page 32: ...sequences Therefore it is very important in addition to a thorough visual inspec tion to check the following points before each ride NOTE Pre operation checks should be made each time the vehicle 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 WARNING EWA11150 If any item in the Pre operation check list is not...

Page 33: ...ystem for leakage 6 14 Front brake Check operation If soft or spongy have Yamaha dealer bleed hydraulic system Check lever free play Adjust if necessary Check brake pads for wear Replace if necessary Check fluid level in reservoir If necessary add recommended brake fluid to specified level Check hydraulic system for leakage 6 25 Rear brake Check operation If soft or spongy have Yamaha dealer bleed...

Page 34: ...Correct if necessary 6 19 6 21 Brake and shift pedals Make sure that operation is smooth Lubricate pedal pivoting points if necessary 6 27 Brake and clutch levers Make sure that operation is smooth Lubricate lever pivoting points if necessary 6 28 Centerstand sidestand Make sure that operation is smooth Lubricate pivots if necessary 6 28 Chassis fasteners Make sure that all nuts bolts and screws a...

Page 35: ...ulled and the sid estand up WARNING EWA10290 Before starting the engine check the function of the igni tion circuit cut off system ac cording to the procedure described on page 3 14 Never ride with the sidestand down 1 Turn the key to ON and make sure that the engine stop switch is set to RUN CAUTION ECA10220 If the fuel level warning light comes on check the fuel level and if nec essary refuel as...

Page 36: ...pushing the start switch or if it does not go off af ter starting with sufficient fuel have a Yamaha dealer check the electrical circuit 5 After starting the engine move the starter choke back halfway CAUTION ECA11130 For maximum engine life always warm the engine up before starting off Never accelerate hard when the engine is cold 6 When the engine is warm turn the starter choke off NOTE The engi...

Page 37: ... ECA10260 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 transmission Always use the clutch while changing gears to avoid damag ing the engine transmission and drive train which...

Page 38: ...ator light should come on EAU16720 Recommended shift points The recommended shift points during acceleration and deceleration are shown in the table below EAU16841 Engine break in There is never a more important period in the life of your engine than the period between 0 and 1600 km 1000 mi For this reason you should read the follow ing material carefully Since the engine is brand new do not put a...

Page 39: ...f the tachometer red zone If any engine trouble should oc cur during the engine break in period immediately have a Yamaha dealer check the vehi cle EAU17200 Parking When parking stop the engine and then remove the key from the main switch WARNING EWA10310 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 ...

Page 40: ...F YOUR MOTORCYCLE IS IMPOR TANT IN ORDER TO ENJOY LONG PLEASURABLE SERVICE ESPE CIALLY IMPORTANT ARE THE MAIN TENANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER AIR BUT ARE ALSO VITAL TO PROPER EN GINE OPERATION AND MAXIMUM PERFORMANCE IN THE FOLLOW ING PERIODIC MAINTENANCE CHARTS THE SERVICES RELATED TO EMISSIONS CONTROL ARE GROUPED SEPARATELY THESE S...

Page 41: ...ain 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 WARNING EWA10340 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 any changes 5GK14 book Page 2 Friday April 11 2003 1 07 PM ...

Page 42: ...uel line Check fuel hose for cracks or damage Replace if necessary 2 Fuel filter Replace Replace 3 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 4 Valve clearance Check and adjust valve clearance when engine is cold Every 26600 mi 42000 km 5 Crankcase breather system Check breather hose for cracks or damage Replace if necessary 6 Carbu...

Page 43: ...attery Check specific gravity and breath er hose for proper operation 3 Clutch Check operation and fluid leak age See NOTE Correct if necessary 4 Front brake Check operation fluid level and for fluid leakage See NOTE Replace brake pads if necessary 5 Rear brake Check operation fluid level and for fluid leakage See NOTE Replace brake pads if necessary 6 Wheel bearings Check bearings for smooth oper...

Page 44: ...and pivot Check operation Apply lithium soap based grease all purpose grease lightly 12 Sidestand switch Check operation and replace if necessary 13 Front fork Check operation and for oil leak age Replace if necessary 14 Engine oil Change warm engine before draining 15 Engine oil filter ele ment Clean 16 Engine oil filter car tridge Replace No ITEM ROUTINE INITIAL ODOMETER READINGS 600 mi 1000 km ...

Page 45: ...y check the brake and clutch fluid levels and fill the reservoirs as required 17 Cooling system Check hoses for cracks or dam age Replace if necessary Change with ethylene glycol anti freeze coolant every 24 months Change 18 Final gear oil Check oil level and for oil leakage Change at initial 600 mi 1000 km or 1 month and thereafter every 16000 mi 25000 km or 24 months Change Change 19 Control and...

Page 46: ...e 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 5GK14 book Page 7 Friday April 11 2003 1 07 PM ...

Page 47: ... 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 EAU19180 Panel A To remove the panel 1 Remove cowling A See page 6 8 2 Remove the screws and then take the panel off To install the panel 1 Place the panel in...

Page 48: ... spark plugs can re veal the condition of the engine To remove a spark plug 1 Remove the spark plug cap 2 Remove the spark plug as shown with the spark plug wrench includ ed in the owner s tool kit To check the spark plugs 1 Check that the porcelain insulator around the center electrode on each spark plug is a medium to light tan the ideal color when the vehicle is ridden normally 2 Check that all...

Page 49: ...possible 4 Install the spark plug cap EAU19871 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 vehicle on the center stand NOTE Make sure that the vehicle is pos...

Page 50: ...an 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 4 Remove the oil filter cartridge with an oil filter wrench NOTE An oil filter wrench is available at a Yamaha dealer 5 Apply a thin coat of engine oil to the O ring of the new oil filter car tridge 1...

Page 51: ...with a diesel speci fication of CD or oils of a high er quality than specified In addition do not use oils labeled ENERGY CONSERVING II or higher Make sure that no foreign mate rial enters the crankcase 9 Start the engine and then let it idle for several minutes while checking it for oil leakage If oil is leaking im mediately turn the engine off and check for the cause 1 O ring 1 Torque wrench Tig...

Page 52: ...RNING EWA10370 Make sure that no foreign mate rial enters the final gear case Make sure that no oil gets on the tire or wheel To check the final gear oil level 1 Place the vehicle on the center stand NOTE The final gear oil level must be checked on a cold engine Make sure that the vehicle is posi tioned straight up when checking the oil level A slight tilt to the side can result in a false reading...

Page 53: ...sition 2 Remove cowling A See page 6 8 NOTE The coolant level must be checked on a cold engine since the level varies with engine temperature Make sure that the vehicle is posi tioned 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 cool ant reservoir NOTE The coolant should be between the minimum and maximum level...

Page 54: ... reduced WARNING EWA10380 Never attempt to remove the radiator 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 40 for further instructions EAU20390 To change the coolant 1 Place the vehicle on the center stand and let the engine cool if necessary 2 Remove cowling A and pane...

Page 55: ...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 coolant into the radiator until it is full 1 Water pump drain bolt 1 Screw 1 Rubber coolant drain plug Tightening torque Water pump drain bolt 43 Nm 4 3 m kgf 31 ft lbf Antifree...

Page 56: ...tor 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 the vehicle for coolant leakage If coolant is le...

Page 57: ...he engine should never be op erated without the air filter ele ment installed otherwise the piston s and or cylinder s may become excessively worn 6 Install the air filter case cover by in stalling the screws 7 Install the cowling EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission control sys tem which require very sophisticated adjustment Therefore a...

Page 58: ...tervals specified in the periodic maintenance and lubrication chart EAU32380 Tires To maximize the performance durabil ity and safe operation of your motor cycle 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 WARNING EWA10500 The tire air pressure must be checked and adjusted on cold tires...

Page 59: ...s crosswise lines minimum tread depth if the tire has a nail or glass fragments in it or if the sidewall is cracked con tact a Yamaha dealer immediately and have the tire replaced WARNING EWA10580 It is dangerous to ride with a worn out tire When a tire tread begins to show crosswise lines have a Yamaha dealer replace the tire immediately The replacement of all wheel and brake related parts includ...

Page 60: ... sure according to the operating conditions EAU21980 Cast wheels To maximize the performance durabil ity and safe operation of your motor cycle note the following points regarding the specified wheels The wheel rims should be checked for cracks bends warpage or damage before each ride If any damage is found have a Yamaha dealer replace the wheel Do not attempt even the smallest repair to the wheel...

Page 61: ...ries are designed and tested to be compatible with your motorcycle Please consider Genu ine Yamaha Parts and Accessories before making a purchase Use of non Yamaha approved accessories or replacement parts may cause loss of handling stability and riding safety Since Yamaha cannot control the quality of accessories or parts manufactured by other companies Yamaha cannot be held liable for any conseq...

Page 62: ...as shown Periodically check the brake le ver free play and if necessary adjust it as follows 1 Loosen the locknut at the brake le ver 2 To increase the brake lever free play turn the adjusting bolt in di rection a To decrease the brake lever free play turn the adjusting bolt in direction b 3 Tighten the locknut WARNING EWA10630 After adjusting the brake lever free play check the free play and make...

Page 63: ...raulic system will diminish the braking performance which may result in loss of control and an acci dent EAU22270 Adjusting the rear brake light switch The rear brake light switch which is ac tivated by the brake pedal is properly adjusted when the brake light comes on just before braking takes effect If necessary adjust the brake light switch as follows Turn the adjusting nut while holding the re...

Page 64: ... replace the brake pads as a set EAU22680 Checking the brake and clutch fluid levels Front brake Rear brake Clutch Insufficient brake fluid may allow air to enter the brake or clutch systems pos sibly causing them to become ineffec tive Before riding check that the brake fluid is above the minimum level mark and replenish if necessary A low brake fluid level may indicate worn brake pads and or bra...

Page 65: ...refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Brake fluid may deteriorate paint ed surfaces or plastic parts Al ways clean up spilled fluid immediately As the brake pads wear it is nor mal for the brake fluid level to grad ually go down However if the brake fluid level goes down sud denly have a Yamaha dealer check the cause EAU22750 Changing ...

Page 66: ... cable movement Replace damaged ca bles as soon as possible to prevent unsafe conditions EAU23110 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 EAU23131 Checking and lubricating the brake and shift pedals T...

Page 67: ...he centerstand and sidestand should be checked before each ride and the pivots and metal to metal contact surfaces should be lubri cated if necessary WARNING EWA10740 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 pur pose grease Recommended lubricant Lithium soap based grease all pur p...

Page 68: ...dition WARNING EWA10750 Securely support the vehicle 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 vehicle on a level sur face and hold it in an upright posi tion 2 While applying the front brake push down hard on the handlebars several times to check if the front fork compresses and rebounds sm...

Page 69: ...ely support the vehicle 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 steering EAU23290 Checking the wheel bearings The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrica tion char...

Page 70: ...e level in the battery NOTE The electrolyte should be between the minimum and maximum level marks 3 If the electrolyte is at or below the minimum level mark continue with the following steps 4 Remove the rider seat See page 3 9 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 Disconnect the coup...

Page 71: ...vide sufficient ventilation when charging it in an enclosed space KEEP THIS AND ALL BATTER IES OUT OF THE REACH OF CHILDREN CAUTION ECA10610 Use only distilled water as tap water contains minerals that are harmful to the battery 10 Check and if necessary correct the breather hose routing 11 Install the ignition coil assemblies by installing the bolts 12 Connect the couplers 13 Connect and tighten ...

Page 72: ...After installation make sure that the battery leads are properly con nected to the battery terminals and that the breather hose is properly routed in good condition and not obstructed CAUTION ECA10600 If the breather hose is positioned in such a way that the frame is ex posed to electrolyte or gas expelled from the battery the frame could suffer structural and external dam ages EAU23570 Replacing ...

Page 73: ...ion to check if the device operates 4 If the fuse immediately blows again have a Yamaha dealer check the electrical system EAU23780 Replacing the headlight bulb This model is equipped with a quartz bulb headlight If the headlight bulb burns out replace it as follows 1 Remove the headlight unit by re moving the screws 2 Disconnect the headlight coupler and then remove the bulb cover 1 Headlight fus...

Page 74: ...rom 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 a cloth moistened with al cohol or thinner 5 Install the headlight bulb cover and then connect the coupler 6 Install the headlight unit by install ing the screws 7 Have a Yamaha dealer adjust the headligh...

Page 75: ...ere is no danger of it falling over 1 Place the motorcycle on the cen terstand 2 Disconnect the speedometer ca ble from the front wheel 3 Remove the brake calipers by re moving the bolts CAUTION ECA11060 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...

Page 76: ... the front wheel axle pinch bolt 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 EAU25080 Rear wheel EAU25100 To remove the rear wheel WARNING EWA10820 It is advisable to have a Yamaha dealer service the wheel Securely support the motor cycle so that there is no danger of it fall...

Page 77: ...e right to sepa rate it from the final gear case and then remove it CAUTION ECA11180 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 EAU25500 To install the rear wheel 1 Apply a light coating of lithium soap based grease to the splines of the final gear case and wheel hub 2 Install the wheel brake caliper brack...

Page 78: ... thorough inspection before shipment from the factory trouble may occur dur ing operation Any problem in the fuel compression or ignition systems for example can cause poor starting and 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 s...

Page 79: ...k 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 s...

Page 80: ...he hissing 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...

Page 81: ... leave the cleaner on the af fected area any longer than in structed Also thoroughly rinse the area off with water immedi ately dry it and then apply a cor rosion protection spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic part...

Page 82: ...ion After cleaning 1 Dry the motorcycle with a chamois or an absorbing cloth 2 Use a chrome polish to shine chrome aluminum and stainless steel parts including the exhaust system Even the thermally in duced discoloring of stainless steel exhaust systems can be re moved through polishing 3 To prevent corrosion it is recom mended to apply a corrosion pro tection spray on all metal including chrome a...

Page 83: ...ock that has an OFF posi tion Turn the fuel cock lever to OFF 3 Drain the carburetor float cham bers by loosening the drain bolts this will prevent 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 cyl...

Page 84: ...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 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 th...

Page 85: ...Imp qt Final gear oil Type SAE80API GL 4 hypoid gear oil or multi grade hypoid gear oil SAE80W 90 Quantity 0 20 L 0 21 us qt 0 18 Imp qt Cooling system Coolant reservoir capacity 0 30 L 0 32 us qt 0 26 Imp qt Radiator capacity including all routes 3 05 L 3 22 us qt 2 68 Imp qt Air filter Air filter element Dry element Fuel Recommended fuel Regular unleaded gasoline only ZAF Unleaded gasoline only ...

Page 86: ...Tire air pressure measured on cold tires Loading condition 0 0 90 0 kg 0 198 lb Front 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Loading condition 90 0 216 0 kg 198 476 lb Front 225 kPa 33 psi 2 25 kgf cm Rear 250 kPa 36 psi 2 50 kgf cm Front wheel Wheel type Cast wheel Rim size 18M C x MT2 15 Rear wheel Wheel type Cast wheel Rim size 15M C x MT3 50 Front brake Type Dual disc brake...

Page 87: ... 8 0 W 27 0 W 2 Front turn signal position light 12 V 27 0 W 8 0 W 2 Rear turn signal light 12 V 27 0 W 2 Meter lighting 14 V 3 0 W 2 Neutral indicator light 14 V 3 0 W 1 High beam indicator light 14 V 3 0 W 1 Oil level warning light 14 V 3 0 W 1 Turn signal indicator light 14 V 3 0 W 1 Fuel level warning light 14 V 3 0 W 1 Fuses Main fuse 30 0 A Headlight fuse 15 0 A Signaling system fuse 10 0 A ...

Page 88: ... 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 EAU26400 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 motorcycle and...

Page 89: ...model label is affixed under cowl ing A See page 6 8 Record the infor mation on this label in the space provided This information will be need ed when ordering spare parts from a Yamaha dealer 1 Model label 5GK14 book Page 2 Friday April 11 2003 1 07 PM ...

Page 90: ...vestigation and if it finds that a safety defect exists in a 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 T...

Page 91: ...hicle 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 ...

Page 92: ...eminder that maintenance work is required It is not acceptable proof of maintenance work Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 24000 mi 37000 km or 36 months 28000 mi 43000 k...

Page 93: ...NFORMATION 9 6 9 36000 mi 55000 km or 54 months 40000 mi 61000 km or 60 months Maintenance interval Date of service Mileage Servicing dealer name and address Remarks 5GK14 book Page 6 Friday April 11 2003 1 07 PM ...

Page 94: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY 5GK14 book Page 7 Friday April 11 2003 1 07 PM ...

Page 95: ...CONSUMER INFORMATION 9 8 9 5GK14 book Page 8 Friday April 11 2003 1 07 PM ...

Page 96: ...red repairs There s no deductible to pay and repairs aren t pro rated You don t have any out of pocket expenses for covered repairs In addition Travel and Recreation Interruption Protection TRIP is included at no extra cost TRIP gives you up to 150 reimbursement per occurrence for any reasonable expenses you incur because your Yamaha needs covered service replacement vehicle rental emergency towin...

Page 97: ...cked protection even after your Yamaha Limited Warranty expires A special note If visiting your dealer isn t convenient contact Yamaha with your Primary ID number your frame number We ll be happy to help you get the Y E S coverage you need Yamaha Service Marketing P O Box 6555 Cypress CA 90630 1 866 YES EXTD 1 866 937 3983 5GK14 book Page 10 Friday April 11 2003 1 07 PM ...

Page 98: ...placing 6 33 H Handlebar switches 3 3 Headlight bulb replacing 6 34 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 14 Indicator and warning lights 3 1 K Key identification number 9 1 L Labels location of 1 5 M Main switch 3 1 Maintenance and lubrication periodic 6 4 Maintenance emission control system 6 3 Maintenance ...

Page 99: ...ht bulb or tail brake light bulb replacing 6 35 Turn signal switch 3 4 V Valve clearance adjusting 6 19 V Boost 3 13 Vehicle identification number 9 1 W Warranty extended 9 9 Warranty limited 9 7 Wheel bearings checking 6 30 Wheel front 6 36 Wheel rear 6 37 Wheels 6 21 5GK14 book Page 2 Friday April 11 2003 1 07 PM ...

Page 100: ...PRINTED IN JAPAN 2003 04 0 4 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD ...

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