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Yamaha VMX EAU10041, Owner'S Manual

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

6

any consequences caused by the
use of items which have not been
approved by Yamaha.

EAU22071

Clutch lever free play

Since this model is equipped with a hy-
draulic clutch, adjusting the clutch lever
free play is not needed. However, it is
necessary to check the clutch fluid level
and check the hydraulic system for
leakage before each ride. If the clutch
lever free play does become excessive,
and shifting becomes rough or clutch
slippage occurs, causing poor acceler-
ation, there may be air in the clutch sys-
tem. If there is air in the hydraulic
system, have a Yamaha dealer bleed
the system before operating the motor-
cycle.

EAU22092

Adjusting the brake lever free
play

The brake lever free play should mea-
sure 2.0–5.0 mm (0.08–0.20 in) 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 screw in di-
rection (a). To decrease the brake
lever free play, turn the adjusting
screw in direction (b).

3. Tighten the locknut.

1. Locknut

2. Brake lever free play adjusting screw
3. Brake lever free play

U5GK15E0.book Page 23 Tuesday, April 13, 2004 3:52 PM

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Summary of Contents for VMX EAU10041

Page 1: ...PRINTED IN JAPAN 2004 04 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5GK 28199 15 LIT 11626 18 18 VMX12T C OWNER S MANUAL...

Page 2: ...EAU10041 U5GK15E0 book Page 1 Tuesday April 13 2004 3 52 PM...

Page 3: ...ycle 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...

Page 4: ...onsult your Yamaha dealer WARNING EWA10010 PLEASE READ THIS MANUAL AND THE YOU AND YOUR MOTORCYCLE RIDING TIPS BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE DO NOT ATTEMPT TO OPERA...

Page 5: ...INED 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 RELIABILITY OF THIS MOTOR...

Page 6: ...tion U S A 1st edition April 2004 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 L...

Page 7: ...art 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 Canister for California only 6 10...

Page 8: ...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...

Page 9: ...ents have been caused by an automobile driver who did not see the motorcycle Making yourself conspicuous ap pears to be very effective in reduc ing the chance of this type of accident Therefore Wear a...

Page 10: ...hield 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 preventi...

Page 11: ...se provided 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...

Page 12: ...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...

Page 13: ...SAFETY INFORMATION 1 5 1 EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle U5GK15E0 book Page 5 Tuesday April 13 2004 3 52 PM...

Page 14: ...SAFETY INFORMATION 1 6 1 1 3 2 CALIFORNIA ONLY 4 5 00 U5GK15E0 book Page 6 Tuesday April 13 2004 3 52 PM...

Page 15: ...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 ho...

Page 16: ...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 11 9 Engine oil level check window page 6 11 10 Br...

Page 17: ...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...

Page 18: ...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...

Page 19: ...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 t...

Page 20: ...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...

Page 21: ...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 sw...

Page 22: ...lutch 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 clu...

Page 23: ...ank 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 counte...

Page 24: ...ngine 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...

Page 25: ...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...

Page 26: ...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...

Page 27: ...ting 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 plac...

Page 28: ...Both shock absorber assemblies are equipped with a spring preload adjust ing ring and a damping force adjusting knob CAUTION ECA10100 Never attempt to turn an adjusting mechanism beyond the maximum or...

Page 29: ...orbers contain highly pressurized nitrogen gas For proper handling read and under stand the following information be fore handling the shock absorbers The manufacturer cannot be held re sponsible for...

Page 30: ...cated on the left side of the frame Raise the sidestand or lower it with your foot while holding the vehicle upright NOTE The built in sidestand switch is part of the ignition circuit cut off system w...

Page 31: ...the clutch lever is not pulled It prevents starting when the trans mission is in gear and the clutch le ver is pulled but the sidestand is still down It cuts the running engine when the transmission...

Page 32: ...r 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 reliab...

Page 33: ...uences 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...

Page 34: ...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...

Page 35: ...rect if necessary 6 20 6 22 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 Lubri...

Page 36: ...ed 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 s...

Page 37: ...hing 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 CA...

Page 38: ...A10260 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 lubri...

Page 39: ...r 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 i...

Page 40: ...he 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...

Page 41: ...YOUR VEHICLE IS IMPORTANT IN ORDER TO ENJOY LONG PLEA SURABLE SERVICE ESPECIALLY IMPORTANT ARE THE MAINTE NANCE SERVICES RELATED TO EMISSIONS CONTROL THESE CONTROLS NOT ONLY FUNCTION TO ENSURE CLEANER...

Page 42: ...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...

Page 43: ...cessary 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...

Page 44: ...heck specific gravity and breath er hose for proper operation 3 Clutch Check operation and fluid leak age Correct if necessary 4 Front brake Check operation fluid level and for fluid leakage Replace b...

Page 45: ...ch le ver pivot shafts Apply lithium soap based grease all purpose grease lightly 14 Brake and shift ped al pivot shafts Apply lithium soap based grease all purpose grease lightly 15 Centerstand and s...

Page 46: ...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 23 Control and meter cables Apply Yamaha chai...

Page 47: ...ch systems After disassembling the brake or clutch master cylinders caliper cylinders or clutch release cylinder always change the fluid Regularly check the brake and clutch fluid levels and fill the...

Page 48: ...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 p...

Page 49: ...ark 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 ch...

Page 50: ...ot available when installing a spark plug a good estimate of the correct torque is 1 4 1 2 turn past finger tight However the spark plug should be tightened to the speci fied torque as soon as possibl...

Page 51: ...tes until the oil set tles and then check the oil level through the check window located at the bottom right side of the crankcase NOTE The engine oil should be between the minimum and maximum level m...

Page 52: ...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 specifie...

Page 53: ...10 Turn the engine off and then check the oil level and correct it if necessary EAU20000 Final gear oil The final gear case must be checked for oil leakage before each ride If any leakage is found hav...

Page 54: ...e If oil is leaking check for the cause EAU20070 Coolant The coolant level should be checked before each ride In addition the cool ant must be changed at the intervals specified in the periodic mainte...

Page 55: ...ant have a Yamaha dealer check the antifreeze content of the coolant as soon as possible otherwise the effectiveness of the coolant will be reduced WARNING EWA10380 Never attempt to remove the radiato...

Page 56: ...gine 9 After the coolant is completely drained thoroughly flush the cool ing system with clean tap water 10 Install the water pump drain bolt and then tighten it to the specified torque NOTE Check the...

Page 57: ...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...

Page 58: ...he 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 elem...

Page 59: ...ree play The throttle cable free play should mea sure 3 0 5 0 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 EAU2...

Page 60: ...to the center of the vehicle and distribute the weight evenly from side to side Properly adjust the suspension for your load and check the condition and pres sure of your tires NEVER OVER LOAD YOUR V...

Page 61: ...he tires listed below have been ap proved for this model by Yamaha Motor Co Ltd WARNING EWA10600 This motorcycle is fitted with super high speed tires Note the following points in order to make the mo...

Page 62: ...replacing a tire tighten the valve stem nut and locknut to the specified torques EAU22011 Accessories and replacement parts WARNING EWA10621 This vehicle is not designed to pull a trailer or to be at...

Page 63: ...ation there may be air in the clutch sys tem If there is air in the hydraulic system have a Yamaha dealer bleed the system before operating the motor cycle EAU22092 Adjusting the brake lever free play...

Page 64: ...tch 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 a To make the brake light come on l...

Page 65: ...hat the top of the brake or clutch fluid reservoir is level Use only the recommended quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor braking or clutch performan...

Page 66: ...cylinders and cali pers as well as the 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 Re...

Page 67: ...d be lubricated or replaced at the intervals specified in the periodic maintenance chart EAU23131 Checking and lubricating the brake and shift pedals The operation of the brake and shift pedals should...

Page 68: ...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 EAU23250...

Page 69: ...o check if the front fork compresses and rebounds smoothly CAUTION ECA10590 If any damage is found or the front fork does not operate smoothly have a Yamaha dealer check or re pair it EAU23280 Checkin...

Page 70: ...ha dealer check the wheel bearings EAU23351 Battery A poorly maintained battery will corrode and discharge quickly The electrolyte level battery lead connections and breather hose routing should be ch...

Page 71: ...m 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 WARNING...

Page 72: ...e starter motor lead to the starter motor relay WARNING EWA10780 Pass the positive battery lead and starter lead through the hole in the ignition coil bracket as shown Im proper routing of these leads...

Page 73: ...structural and external dam ages EAU23570 Replacing the fuses The main fuse box is located under the rider seat See page 3 9 The fuse box which contains the fuses for the individual circuits is locat...

Page 74: ...acing 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...

Page 75: ...dlight 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 deal...

Page 76: ...ake 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 t...

Page 77: ...ion 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 f...

Page 78: ...l 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...

Page 79: ...r 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...

Page 80: ...he vehicle Remove the spark plugs and check the electrodes 3 Ignition Wet Dry Wipe off with a dry cloth and correct the spark plug gaps or replace the spark plugs Have a Yamaha dealer check the vehicl...

Page 81: ...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...

Page 82: ...ave 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 d...

Page 83: ...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 du...

Page 84: ...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 in...

Page 85: ...ls 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 moi...

Page 86: ...ge replacement 3 50 L 3 70 US qt 3 08 Imp qt With oil filter cartridge replacement 3 80 L 4 02 US qt 3 34 Imp qt Final gear oil Type SAE80 API GL 4 Hypoid gear oil or multi grade hypoid gear oil SAE80...

Page 87: ...Rear tire Type Tubeless Size 150 90 15M C 74V Manufacturer model BRIDGESTONE G526 Manufacturer model DUNLOP K525 Loading Maximum load 215 kg 474 lb CAL ZAF 216 kg 476 lb U49 Total weight of rider pas...

Page 88: ...eadlight Bulb type Halogen bulb Bulb voltage wattage x quantity Headlight 12 V 60 W 55 0 W 1 Tail brake light 12 V 8 0 27 0 W 2 Front turn signal position light 12 V 23 W 8 0 W 2 Rear turn signal ligh...

Page 89: ...ntification 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 numb...

Page 90: ...el 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 la...

Page 91: ...tigation 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 deale...

Page 92: ...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...

Page 93: ...nder 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 4...

Page 94: ...RMATION 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 U5GK15E0 book Page 6 Tuesday April 13...

Page 95: ...CONSUMER INFORMATION 9 7 9 EAU26661 YAMAHA MOTOR CORPORATION U S A STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY U5GK15E0 book Page 7 Tuesday April 13 2004 3 52 PM...

Page 96: ...CONSUMER INFORMATION 9 8 9 U5GK15E0 book Page 8 Tuesday April 13 2004 3 52 PM...

Page 97: ...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 inclu...

Page 98: ...d 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...

Page 99: ...eplacing 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...

Page 100: ...light 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 W...

Page 101: ...PRINTED IN JAPAN 2004 04 0 3 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 5GK 28199 15 LIT 11626 18 18 VMX12T C OWNER S MANUAL...

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