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PERIODIC MAINTENANCE AND MINOR REPAIR

6-34

CAUTION:

ECA10640

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.

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.

3. Remove the headlight bulb holder

by turning it counterclockwise, and
then remove the defective bulb.

Specified fuses:

Main fuse:

30.0 A

Headlight fuse:

15.0 A

Signaling system fuse:

10.0 A

Radiator fan fuse:

10.0 A

Ignition fuse:

10.0 A

1. Screw

1. Headlight bulb holder

1. Do not touch the glass part of the bulb.

U5GK15E0.book Page 34 Tuesday, April 13, 2004 3:52 PM

Содержание Vmax VMX12T(C)

Страница 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 ...

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

Страница 3: ...cycle 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 st...

Страница 4: ...consult 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 OPERATE THIS MOTOR CYCLE UNTIL YOU HAVE ATTAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WA...

Страница 5: ...AINED 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 MOTORCYCLE U5GK15E0 book Page 2 Tuesday April 13 2004 3 52 PM ...

Страница 6: ...ation 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 LIT 11626 18 18 AFFIX DEALER LABEL HERE U5GK15E0 book Page 3 Tuesday April 13 2004 3 52 PM ...

Страница 7: ...hart 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 Engine oil and oil filter cartridge 6 11 Final gear oil 6 13 Coolant 6 14 Cleaning the air filter element 6 18 Adjusting the carburetors 6 19 Adjusting the throttle cable free play 6 19 Adjusting the...

Страница 8: ...7 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 9 9 U5GK15E0 book Page 2 Tuesd...

Страница 9: ...dents 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 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 othe...

Страница 10: ...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...

Страница 11: ...ose 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 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 t...

Страница 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 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 mot...

Страница 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 ...

Страница 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 ...

Страница 15: ...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 U5GK15E0 book Page 1 Tuesday April 13 2004 3 52 PM ...

Страница 16: ...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 11 9 Engine oil level check window page 6 11 10 Brake pedal page 3 6 11 Rear brake fluid reservoir page 6 25 U5GK15E0 book Page 2 Tuesday April 13 2004 3 52 PM ...

Страница 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 gauge page 3 3 U5GK15E0 book Page 3 Tuesday April 13 2004 3 52 PM ...

Страница 18: ...e 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 EAU11001 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 Neutral ind...

Страница 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 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 clutch...

Страница 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 ECA10020 Do not operate the engine if it is overheated EAU12343 Handlebar switches Left Right 1 Tachometer 2 Tachometer red zone 1 Coolant temperature gauge 2 Coolant temperature gauge red zone 1 Dim...

Страница 21: ...t 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 switch ...

Страница 22: ...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 front...

Страница 23: ...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 addition...

Страница 24: ...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 co...

Страница 25: ...n 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 counterclock...

Страница 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 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 holde...

Страница 27: ...sting 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 th...

Страница 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 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 ther...

Страница 29: ...sorbers 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 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 h...

Страница 30: ...ocated 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 which cuts the ignition in certain situations See further down for an explanation of the ignition circuit cut off system WARNING EWA10240 The vehicle must not be ridden with the sidestand down or if t...

Страница 31: ...t 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 is in gear and the sid estand is moved down Periodically check the operation of the ignition circuit cut off system according to the following procedure WARNING EWA10260 The vehicle must be placed on...

Страница 32: ...er 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 s...

Страница 33: ...quences 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 w...

Страница 34: ...m 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 23 6 24 6 25 Rear brake Check operation If soft or spongy have Yamaha dealer...

Страница 35: ...rrect 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 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 are...

Страница 36: ...led 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 s...

Страница 37: ...shing 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 engine...

Страница 38: ...CA10260 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 a...

Страница 39: ...or 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 an ...

Страница 40: ...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 on...

Страница 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 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 SERVIC...

Страница 42: ...n 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 U5GK15E0 book Page 2 Tuesday April 13 2004 3 52 PM ...

Страница 43: ...ecessary 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 Carburetor synchro nization Adjust synchronization of carbu ret...

Страница 44: ...Check 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 brake pads if necessary 5 Rear brake Check operation fluid level and for fluid leakage Replace brake pads if necessary 6 Brake hoses Check for cracks or damage Replace Every 4 years 7 Wheels Check run...

Страница 45: ...tch 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 sidestand pivots Check operation Apply lithium soap based grease all purpose grease lightly 16 Sidestand switch Check operation and replace if necessary 17 Front fork Check operation and for oil leak ...

Страница 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 chain and cable lube or engine oil 10W 30 thor oughly 24 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housin...

Страница 47: ...tch 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 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 hose...

Страница 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 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 the ...

Страница 49: ...park 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 s...

Страница 50: ...not 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 possible 4 Install the spark plug cap EAU19672 Canister for California only This model is equipped with a canister to prevent the discharging of fuel vapor into the atmosphere Check each hose connection Che...

Страница 51: ...utes 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 marks 4 If the engine oil is below the mini mum level mark add sufficient oil of the recommended type to raise it to the correct level To change the engine oil with or without oil filter cartridge rep...

Страница 52: ...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 8 Add the specified amount of the recommended engine oil and then install and tighten the oil filler cap 1 Oil filter cartridge 2 Oil filter wrench 1 O ring 1 Torque wrench Tightening torque...

Страница 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 have a Yamaha deal er check and repair the vehicle In addi tion the final gear oil must be changed as follows at the intervals specified in the periodic maintenance and lubrica tion chart WARNING EWA103...

Страница 54: ...ge 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 maintenance and lubrication chart EAU20241 To check the coolant level 1 Place the vehicle on the center stand and hold it in an upright po sition 2 Remove cowling A See page 6 8 NOTE The coolant level must...

Страница 55: ...lant 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 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 instruct...

Страница 56: ...ngine 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 washer for damage and re place it if necessary 11 Install the rubber coolant drain plugs and then install the cylinder drain plug covers 1 Radiator cap 1 Coolant drain cock 2 Position indicator 1 Wa...

Страница 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 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...

Страница 58: ...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 CAUTION ECA10480 Make sure that the air filter ele ment is properly seated in the air filter case The engine should never be op erated without the air filter ele ment ins...

Страница 59: ...free 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 EAU21400 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 ...

Страница 60: ...e 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 VEHICLE Make sure that the total weight of the cargo rid er passenger and accessories cowling saddlebags etc if ap proved for this model does not ex ceed the maximum load of the vehicle Operation of a...

Страница 61: ...the 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 most ef ficient use of these tires Use only the specified replace ment tires Other tires may run the danger of bursting at super high speeds Brand new tires can have a rela tively poor grip on certain ...

Страница 62: ...r 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 attached to a sidecar The accessories or replacement parts you choose for your vehicle should be designed specifically for this model and they must be se curely mounted to maintain the in herent stabil...

Страница 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 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 ve...

Страница 64: ...itch 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 later turn the adjusting nut in direction b EAU22311 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 maintenan...

Страница 65: ...that 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 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 ...

Страница 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 Replace every four years EAU23090 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 en...

Страница 67: ...ld 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 be checked before each ride and the pedal pivots should be lu bricated if necessary Recommended lubricant Lithium soap based grease all pur pose grease U5GK15E0 book Page 27 Tuesday April 13 2004 3 ...

Страница 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 Lubricating the rear suspension The pivoting points of the rear suspen sion must be lubricated at the intervals specified in the periodic maintenance and lubrication chart Recommended lubricant Lith...

Страница 69: ...to 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 Checking the steering Worn or loose steering bearings may cause danger Therefore the operation of the steering must be checked as fol lows at the intervals specified in the pe riodic maintenance and lubrica...

Страница 70: ...aha 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 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 vehicle on the center stand 1 Battery 2 Battery br...

Страница 71: ...om 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 EWA10760 Electrolyte is poisonous and dangerous since it contains sul furic acid which causes severe burns Avoid any contact with skin eyes or clothing and al ways shield your eyes when working near ...

Страница 72: ...he 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 could bring about a short circuit causing the engine and lights to fail and pos sibly resulting in an accident 14 Connect and tighten the negative battery lead to the battery 15 Install the rider se...

Страница 73: ...r 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 located un der cowling A See page 6 8 If a fuse is blown replace it as follows 1 Turn the key to OFF and turn off the electrical circuit in question 2 Remove the blown fuse and then install a new fuse of ...

Страница 74: ...lacing 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 3 Remove the headlight bulb holder by turning it counterclockwise and then remove the defective bulb Specified fuses Main fuse 30 0 A Headlight fuse 1...

Страница 75: ...adlight 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 headlight beam if necessary EAU24281 Replacing a turn signal light bulb or the tail brake light bulb 1 Remove the lens by removing the screws 2 Remove the defective bulb by pushing it i...

Страница 76: ...rake 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 EAU24842 To install the front wheel 1 Install the speedometer gear unit into the wheel hub so that the pro jections mesh with the slots 2 Lift the wheel up between the fork legs NOTE Make su...

Страница 77: ...tion 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 falling over 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 to...

Страница 78: ...ll 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 install ing the bolt and the nut 5 Install the axle nut and then slight ly tighten it 6 Take the motorcycle off the center stand so that the rear wheel is on the ground 7 Tighten the rear wheel axle...

Страница 79: ...or 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 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...

Страница 80: ...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 slo...

Страница 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 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 t...

Страница 82: ...eave 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 parts ...

Страница 83: ...n 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 and...

Страница 84: ...k 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 cylin...

Страница 85: ...els 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 than 0 C ...

Страница 86: ...dge 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 SAE80W 90 Quantity 0 20 L 0 21 US qt 0 18 Imp qt Cooling system Coolant reservoir capacity up to the maximum level mark 0 30 L 0 32 US qt 0 26 Imp qt Radiator capacity including all routes 2 75 L 2 91 US ...

Страница 87: ...0 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 passenger cargo and accessories Tire air pressure measured on cold tires Loading condition 0 90 kg 0 198 lb Front 225 kPa 33 psi 2 25 kgf cm Rear 225 kPa 33 psi 2 25 kgf cm Loading condition 90 215 kg 1...

Страница 88: ...Headlight 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 light 12 V 21 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 F...

Страница 89: ...entification 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 ma...

Страница 90: ...del 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 U5GK15E0 book Page 2 Tuesday April 13 2004 3 52 PM ...

Страница 91: ...stigation 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 Tra...

Страница 92: ...cle 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 Ex...

Страница 93: ...inder 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 km ...

Страница 94: ...ORMATION 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 2004 3 52 PM ...

Страница 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 ...

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

Страница 97: ...d 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 towing ...

Страница 98: ...ed 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 U5GK15E0 book Page 10 Tuesday April 13 2004 3 52 PM ...

Страница 99: ...replacing 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 Maintenanc...

Страница 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 Wheel bearings checking 6 30 Wheel front 6 36 Wheel rear 6 37 Wheels 6 22 U5GK15E0 book Page 2 Tuesday April 13 2004 3 52 PM ...

Страница 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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