Yamaha 2002 Vmax Owners Manual V Max

2015-03-13

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INTRODUCTION
IMPORTANT MANUAL INFORMATION
TABLE OF CONTENTS
SAFETY INFORMATION
DESCRIPTION
INSTRUMENT AND CONTROL FUNCTIONS
PRE-OPERATION CHECKS
OPERATION AND IMPORTANT RIDING POINTS
PERIODIC MAINTENANCE AND MINOR REPAIR
MOTORCYCLE CARE AND STORAGE
SPECIFICATIONS
CONSUMER INFORMATION
INDEX

LIT-11626-15-11 5GK-28199-12

VMX12P

VMX12PC

OWNER’S MANUAL

PRINTED IN JAPAN

2001 · 4 - 0.9 × 1 CR

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

EAU03438

EAU00002 INTRODUCTION

Congratulations on your purchase of the Yamaha VMX12/VMX12C. This model is

the result of Yamaha’s vast experience in the production of fine sporting, touring, and

pacesetting racing machines. It represents the high degree of craftsmanship and

reliability that have made Yamaha a leader in these fields.

This manual will give you an understanding of the operation, inspection, and basic

maintenance of this motorcycle. If you have any questions concerning the operation

or maintenance of your motorcycle, please consult a Yamaha dealer.

The design and manufacture of this Yamaha motorcycle fully comply with the emis-

sions standards for clean air applicable at the date of manufacture. Yamaha has met

these standards without reducing the performance or economy of operation of the

motorcycle. To maintain these high standards, it is important that you and your

Yamaha dealer pay close attention to the recommended maintenance schedules and

operating instructions contained within this manual.

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

EAU00003

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING Failure to follow WARNING instructions could result in severe injury or death to the

motorcycle operator, a bystander or a person inspecting or repairing the motorcycle.

CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the

motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

NOTE:

●This manual should be considered a permanent part of this motorcycle and should remain

with it even if the motorcycle is subsequently sold.

●Yamaha continually seeks advancements in product design and quality. Therefore, while

this manual contains the most current product information available at the time of printing,

there may be minor discrepancies between your motorcycle and this manual. If you have

any questions concerning this manual, please consult your Yamaha dealer.

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

IMPORTANT MANUAL INFORMATION

EW000000

WARNING

PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING

TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTOR-

CYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT-

TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES

AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.

REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING

SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELI-

ABILITY OF THIS MOTORCYCLE.

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

IMPORTANT MANUAL INFORMATION

AFFIX DEALER

LABEL HERE

EAU03336

VMX12P/VMX12PC

OWNER’S MANUAL

1st Edition, March 2001

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-11626-15-11

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

TABLE OF CONTENTS

1 SAFETY INFORMATION 1

2 DESCRIPTION 2

3 INSTRUMENT AND CONTROL FUNCTIONS 3

4 PRE-OPERATION CHECKS 4

5 OPERATION AND IMPORTANT RIDING POINTS 5

6 PERIODIC MAINTENANCE AND MINOR REPAIR 6

7 MOTORCYCLE CARE AND STORAGE 7

8 SPECIFICATIONS 8

9 CONSUMER INFORMATION 9

INDEX

EAU00009

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SAFETY INFORMATION

Safe riding .......................................................................................... 1-1

Protective apparel .............................................................................. 1-3

Modifications ...................................................................................... 1-3

Loading and accessories ................................................................... 1-3

Gasoline and exhaust gas.................................................................. 1-5

Location of important labels ............................................................... 1-7

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

1-1

SAFETY INFORMATION EAU00014*

MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DE-

PENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF

THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BE-

FORE RIDING THIS MOTORCYCLE.

HE OR SHE SHOULD:

1. OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF

MOTORCYCLE OPERATION.

2. OBSERVE THE WARNINGS AND MAINTENANCE REQUIREMENTS IN THE OWNER’S MANUAL.

3. OBTAIN QUALIFIED TRAINING IN SAFE AND PROPER RIDING TECHNIQUES.

4. OBTAIN PROFESSIONAL TECHNICAL SERVICE AS INDICATED BY THE OWNER’S MANUAL

AND/OR WHEN MADE NECESSARY BY MECHANICAL CONDITIONS.

Safe riding

1. Always make pre-operation checks. Careful checks may help prevent an accident.

2. This motorcycle is designed to carry the operator and a passenger.

3. The failure of motorists to detect and recognize motorcycles in traffic is the predominating cause of

automobile/motorcycle accidents. Many accidents have been caused by an automobile driver who

did not see the motorcycle. Making yourself conspicuous appears to be very effective in reducing the

chance of this type of accident.

Therefore:

a. Wear a brightly colored jacket.

b. Use extra caution when you are approaching and passing through intersections, since intersec-

tions are the most likely places for motorcycle accidents to occur.

c. Ride where other motorists can see you. Avoid riding in another motorist’s blind spot.

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SAFETY INFORMATION

1-2

4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in

accidents do not even have a current motorcycle license.

a. Make sure that you are qualified and that you only lend your motorcycle to other qualified opera-

tors.

b. Know your skills and limits. Staying within your limits may help you to avoid an accident.

c. We recommend that you practice riding your motorcycle where there is no traffic until you have

become thoroughly familiar with the motorcycle and all of its controls.

5. Many accidents have been caused by error of the motorcycle operator. A typical error made by the

operator is veering wide on a turn due to EXCESSIVE SPEED or undercornering (insufficient lean

angle for the speed).

a. Always obey the speed limit and never travel faster than warranted by road and traffic conditions.

b. Always signal before turning or changing lanes. Make sure that other motorists can see you.

6. The posture of the operator and passenger is important for proper control.

a. The operator should keep both hands on the handlebar and both feet on the operator footrests

during operation to maintain control of the motorcycle.

b. The passenger should always hold onto the operator, the seat strap or grab bar, if equipped, with

both hands and keep both feet on the passenger footrests.

c. Never carry a passenger unless he or she can firmly place both feet on the passenger footrests.

7. Never ride under the influence of alcohol or other drugs.

8. This motorcycle is designed for on-road use only. It is not suitable for off-road use.

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SAFETY INFORMATION

1-3

Protective apparel

The majority of fatalities from motorcycle accidents are the result of head injuries. The use of a safety

helmet is the single most critical factor in the prevention or reduction of head injuries.

1. Always wear an approved helmet.

2. Wear a face shield or goggles. Wind in your unprotected eyes could contribute to an impairment of vi-

sion that could delay seeing a hazard.

3. The use of a jacket, heavy boots, trousers, gloves, etc., is effective in preventing or reducing abra-

sions or lacerations.

4. Never wear loose-fitting clothes, otherwise they could catch on the control levers, footrests, or wheels

and cause injury or an accident.

5. Never touch the engine or exhaust system during or after operation. They become very hot and can

cause burns. Always wear protective clothing that covers your legs, ankles, and feet.

6. A passenger should also observe the above precautions.

Modifications

Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment,

may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also

make your motorcycle illegal to use.

Loading and accessories

Adding accessories or cargo to your motorcycle can adversely affect stability and handling if the weight

distribution of the motorcycle is changed. To avoid the possibility of an accident, use extreme caution

when adding cargo or accessories to your motorcycle. Use extra care when riding a motorcycle that has

added cargo or accessories. Here are some general guidelines to follow if loading cargo or adding ac-

cessories to your motorcycle:

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SAFETY INFORMATION

1-4

The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load

limit of VMX12: 476 lb (216 kg) / VMX12C: 474 lb (215 kg). When loading within this weight limit, keep

the following in mind:

1. Cargo and accessory weight should be kept as low and close to the motorcycle as possible. Make

sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbal-

ance or instability.

2. Shifting weights can create a sudden imbalance. Make sure that accessories and cargo are securely

attached to the motorcycle before riding. Check accessory mounts and cargo restraints frequently.

3. Never attach any large or heavy items to the handlebar, front fork, or front fender. These items, in-

cluding such cargo as sleeping bags, duffel bags, or tents, can create unstable handling or a slow

steering response.

Accessories

Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since

Yamaha cannot test all other accessories that may be available, you must personally be responsible for

the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when select-

ing and installing any accessories.

Keep the following guidelines in mind, as well as those provided under “Loading” when mounting acces-

sories.

1. Never install accessories or carry cargo that would impair the performance 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.

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SAFETY INFORMATION

1-5

a. Accessories fitted to the handlebar or the front fork area can create instability due to improper

weight distribution or aerodynamic changes. If accessories are added to the handlebar or front

fork area, they must be as lightweight as possible and should be kept to a minimum.

b. Bulky or large accessories may seriously affect the stability of the motorcycle due to aerodynamic

effects. Wind may attempt to lift the motorcycle, or the motorcycle may become unstable in cross

winds. These accessories may also cause instability when passing or being passed by large ve-

hicles.

c. Certain accessories can displace the operator from his or her normal riding position. This improp-

er position limits the freedom of movement of the operator and may limit control ability, therefore,

such accessories are not recommended.

2. Use caution when adding electrical accessories. If electrical accessories exceed the capacity of the

motorcycle’s electrical system, an electric failure could result, which could cause a dangerous loss of

lights or engine power.

Gasoline and exhaust gas

1. GASOLINE IS HIGHLY FLAMMABLE:

a. Always turn the engine off when refueling.

b. Take care not to spill any gasoline on the engine or exhaust system when refueling.

c. Never refuel while smoking or in the vicinity of an open flame.

2. Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poi-

sonous and may cause loss of consciousness and death within a short time. Always operate your

motorcycle in an area that has adequate ventilation.

3. Always turn the engine off before leaving the motorcycle unattended and remove the key from the

main switch. When parking the motorcycle, note the following:

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SAFETY INFORMATION

1-6

a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pe-

destrians or children are not likely to touch these hot areas.

b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over.

c. Do not park the motorcycle near a flammable source, (e.g., a kerosene heater, or near an open

flame), otherwise it could catch fire.

4. When transporting the motorcycle in another vehicle, make sure that it is kept upright. If the motor-

cycle should lean over, gasoline may leak out of the carburetor or fuel tank.

5. If you should swallow any gasoline, inhale a lot of gasoline vapor, or allow gasoline to get into your

eyes, see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash

the affected area with soap and water and change your clothes.

u5gk12.book Page 6 Wednesday, June 13, 2001 8:55 AM

SAFETY INFORMATION

1-7

EAU02977

Location of important labels

Please read the following important labels carefully before operating this motorcycle.

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SAFETY INFORMATION

1-8

WARNING

BEFORE YOU OPERATE THIS VEHICLE, READ

THE OWNER’S MANUAL AND ALL LABELS.

3MX-2118K-A0

ALWAYS WEAR AN APPROVED MOTORCYCLE

HELMET,

eye protection, and protective clothing.

CAUTION

3JL-28177-A0

Be sure to connect breather hose after

installing battery.

Read owner's manual before servicing battery.

Electrolyte will damage metal parts or paint.

If electrolyte spills, wash area with fresh

water immediately.

5BN-21668-00

Cold tire normal pressure should be set as

follows.

90 kg (198 lbs) ~ maximum load

: 225 kPa, {2.25 kgf/cm2}, 33 psiFRONT

: 250 kPa, {2.50 kgf/cm2}, 36 psiREAR

Up to 90 kg (198 lbs) load

: 225 kPa, {2.25 kgf/cm2}, 33 psiFRONT

: 225 kPa, {2.25 kgf/cm2}, 33 psiREAR

TIRE INFORMATION

EMISSION HOSE ROUTING

CARB. FROM

FUEL TANK

CANISTER

TO ATMOSPHERE

4YN-21686-00

WARNING

PASS LEAD WIRES THROUGH HOLE,

3JP-2415H-A0

as shown. A short circuit could result

from improper routing. This could cause

the engine to stop running and lights to

fail, which could result in an accident.

HOLE

California only

u5gk12.book Page 8 Wednesday, June 13, 2001 8:55 AM

DESCRIPTION

Left view ............................................................................................. 2-1

Right view........................................................................................... 2-2

Controls and instruments ................................................................... 2-3

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

2-1

DESCRIPTION EAU00026

Left view

1. Clutch fluid reservoir (page 6-29)

2. Air filter element (page 6-21)

3. Fuse box (page 6-39)

4. Main fuse box (page 6-39)

5. Owner’s tool kit (page 6-1)

6. Shock absorber assembly spring

preload adjusting ring (page 3-13)

7. Shock absorber assembly damping

force adjusting knob (page 3-13)

8. Helmet holder (page 3-10)

9. Shift pedal (page 3-5)

10. Starter (choke) lever (page 3-8)

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

DESCRIPTION

2-2

Right view

11. Fuel tank cap (page 3-6)

12. Battery (page 6-36)

13. Coolant reservoir (page 6-16)

14. Front brake fluid reservoir (page 6-29)

15. Main switch (page 3-1)

16. Radiator cap (page 6-18)

17. Radiator (page 6-18)

18. Engine oil filter cartridge (page 6-13)

19. Engine oil level check window (page 6-12)

20. Brake pedal (page 3-6)

21. Rear brake fluid reservoir (page 6-29)

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

DESCRIPTION

2-3

Controls and instruments

1. Clutch lever (page 3-5)

2. Left handlebar switches (page 3-3)

3. Speedometer unit (page 3-2)

4. Right handlebar switches (page 3-4)

5. Brake lever (page 3-5)

6. Throttle grip (page 6-22)

7. Tachometer (page 3-3)

8. Coolant temperature gauge (page 3-3)

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

Main switch ........................................................................................ 3-1

Indicator and warning lights ............................................................. 3-1

Speedometer unit .............................................................................. 3-2

Tachometer ....................................................................................... 3-3

Coolant temperature gauge .............................................................. 3-3

Handlebar switches ........................................................................... 3-3

Clutch lever ....................................................................................... 3-5

Shift pedal ......................................................................................... 3-5

Brake lever ........................................................................................ 3-5

Brake pedal ....................................................................................... 3-6

Fuel tank cap ..................................................................................... 3-6

Fuel ................................................................................................... 3-7

Starter (choke) lever .......................................................................... 3-8

Steering lock ..................................................................................... 3-9

Rider seat .......................................................................................... 3-9

Helmet holder .................................................................................. 3-10

Adjusting the front fork .................................................................... 3-11

Adjusting the shock absorber assemblies ....................................... 3-12

Matching the front and rear suspension settings ............................ 3-15

V-Boost ............................................................................................ 3-16

Sidestand ........................................................................................ 3-17

Ignition circuit cut-off system ........................................................... 3-17

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

3-1

EAU00027

INSTRUMENT AND CONTROL FUNCTIONS

EAU00028

Main switch

The main switch controls the ignition

and lighting systems. The various main

switch positions are described below.

EAU00032

All electrical systems are supplied with

power, and the headlight, meter light-

ing, taillight and position lights come

on, and the engine can be started. The

key cannot be removed.

EAU00038

OFF

All electrical systems are off. The key

can be removed.

EAU00051

P (Parking)

The meter lighting, taillight and position

lights are on, but all other electrical sys-

tems are off. The key can be removed.

The key must be pushed in from the

“OFF” position to be turned to “P”.

ECA00043

CAUTION:

Do not use the parking position for

an extended length of time, other-

wise the battery may discharge.

EAU03034

Indicator and warning lights

EAU00062

Neutral indicator light “NEUTRAL”

This indicator light comes on when the

transmission is in the neutral position.

EAU00059

Turn signal indicator light “TURN”

This indicator light flashes when the

turn signal switch is pushed to the left

or right.

1. Push.

2. Release.

3. Turn.

1. Neutral indicator light “NEUTRAL”

2. Turn signal indicator light “TURN”

3. Fuel level warning light “FUEL”

4. High beam indicator light “HIGH BEAM”

5. Oil level warning light “OIL LEVEL”

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INSTRUMENT AND CONTROL FUNCTIONS

3-2

EAU04166

Fuel level warning light “FUEL”

This warning light comes on when the

fuel level drops below approximately

3 L (0.7 Imp gal, 0.8 US 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 fol-

lowing procedure.

1. Set the engine stop switch to

“RUN” and turn the key to “ON”.

2. Shift the transmission into the neu-

tral position or pull the clutch lever.

3. Push the start switch. If the warn-

ing light does not come on, have a

Yamaha dealer check the electri-

cal circuit.

EAU00064

High beam indicator light

“HIGH BEAM”

This indicator light comes on when the

high beam of the headlight is switched

on.

EAU04167

Oil level warning light “OIL LEVEL”

This warning light comes on when the

engine oil level is low.

The electrical circuit of the warning light

can be checked according to the fol-

lowing procedure.

1. Set the engine stop switch to

“RUN” and turn the key to “ON”.

2. Shift the transmission into the neu-

tral position or pull the clutch lever.

3. Push the start switch. If the warn-

ing light does not come on, have a

Yamaha dealer check the electri-

cal circuit.

NOTE:

Even if the oil level is sufficient, the

warning light may flicker when riding on

a slope or during sudden acceleration

or deceleration, but this is not a mal-

function.

EAU00095

Speedometer unit

The speedometer unit is equipped with

a speedometer, an odometer and a

tripmeter. The speedometer shows

riding speed. The odometer shows the

total distance traveled. The tripmeter

shows the distance traveled since it

was last set to zero with the reset knob.

The tripmeter can be used to estimate

the distance that can be traveled with a

full tank of fuel. This information will en-

able you to plan future fuel stops.

1. Tripmeter reset knob

2. Odometer

3. Tripmeter

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INSTRUMENT AND CONTROL FUNCTIONS

3-3

EAU00101

Tachometer

The electric tachometer allows the rider

to monitor the engine speed and keep it

within the ideal power range.

EC000003

CAUTION:

Do not operate the engine in the

tachometer red zone.

Red zone: 8,500 r/min and above

EAU01652

Coolant temperature gauge

With the key in the “ON” position, the

coolant temperature gauge indicates

the temperature 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 motorcycle and let the

engine cool. (See page 6-49 for further

instructions.)

EC000002

CAUTION:

Do not operate the engine if it is

overheated.

EAU00118

Handlebar switches

EAU00122

Dimmer switch “LIGHTS”

Set the switch to “HI” for the high beam

and to “LO” for the low beam.

EAU01189

Turn signal switch “TURN”

To signal a right-hand turn, push this

switch to the right. To signal a left-hand

turn, push the switch to the left. When

released, the switch returns to the cen-

ter position.

1. Tachometer

2. Tachometer red zone

1. Coolant temperature gauge

2. Coolant temperature gauge red zone

1. Dimmer switch “LIGHTS”

2. Turn signal switch “TURN”

3. Horn switch “HORN”

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INSTRUMENT AND CONTROL FUNCTIONS

3-4

Since this model is equipped with a

self-canceling system, the turn signal

lights will self-cancel after the motor-

cycle has traveled both about 150 m

(490 ft) and for approximately 15 sec-

onds. However, the turn signal lights

can also be canceled manually by

pushing the switch in after it has re-

turned to the center position.

NOTE:

The self-canceling system only oper-

ates when the motorcycle is moving, so

that the turn signal lights will not self-

cancel while you are stopped at an in-

tersection.

EAU00130

Horn switch “HORN”

Press this switch to sound the horn.

EAU04184

Engine stop switch “ENGINE STOP”

Set this switch to “ON” before starting

the engine. Set this switch to “OFF” to

stop the engine in case of an emergen-

cy, such as when the motorcycle over-

turns or when the throttle cable is

stuck.

EAU01653

Fuel reserve switch “FUEL”

During normal operation, this switch

should be kept in the “ON” position. If

the fuel warning light comes on while

riding, set the switch to “RES”, refuel as

soon as possible, and then set the

switch back to “ON”.

NOTE:

After switching to “RES”, approximately

3 L (0.7 Imp gal, 0.8 US gal) of fuel re-

main in the fuel tank.

EAU00141

Start switch “START”

Push this switch to crank the engine

with the starter.

EC000005

CAUTION:

See page 5-1 for starting instruc-

tions prior to starting the engine.

1. Engine stop switch “ENGINE STOP”

2. Fuel reserve switch “FUEL”

3. Start switch “START”

u5gk12.book Page 4 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-5

EAU00152

Clutch lever

The clutch lever is located at the left

handlebar grip. To disengage the

clutch, pull the lever toward the handle-

bar grip. To engage the clutch, release

the lever. The lever should be pulled

rapidly and released slowly for smooth

clutch operation.

The clutch lever is equipped with a

clutch switch, which is part of the igni-

tion circuit cut-off system. (See page

3-17 for an explanation of the ignition

circuit cut-off system.)

EAU00157

Shift pedal

The shift pedal is located on the left

side of the engine and is used in com-

bination with the clutch lever when

shifting the gears of the 5-speed con-

stant-mesh transmission equipped on

this motorcycle.

EAU00158

Brake lever

The brake lever is located at the right

handlebar grip. To apply the front

brake, pull the lever toward the handle-

bar grip.

1. Clutch lever 1. Shift pedal 1. Brake lever

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INSTRUMENT AND CONTROL FUNCTIONS

3-6

EAU00162

Brake pedal

The brake pedal is on the right side of

the motorcycle. To apply the rear

brake, press down on the brake pedal.

EAU04168

Fuel tank cap

To remove the fuel tank cap

1. Push the levers on the left and

right side of the rider seat backrest

as shown and slide the rider seat

backrest forward.

2. Insert the key into the lock, and

then turn it 1/4 turn clockwise. The

lock will be released and the fuel

tank cap can be removed.

1. Brake pedal 1. Lever (× 2) 1. Unlock.

u5gk12.book Page 6 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-7

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,

the key cannot be removed if the cap is

not properly installed and locked.

EW000024

WARNING

Make sure that the fuel tank cap is

properly installed before riding.

EAU03753

Fuel

Make sure that there is sufficient fuel in

the tank. Fill the fuel tank to the bottom

of the filler tube as shown.

EW000130

WARNING

●Do not overfill the fuel tank, oth-

erwise it may overflow when the

fuel warms up and expands.

●Avoid spilling fuel on the hot

engine.

EAU00185

CAUTION:

Immediately wipe off spilled fuel

with a clean, dry, soft cloth, since

fuel may deteriorate painted surfac-

es or plastic parts.

EAU04194

ECA00102

CAUTION:

Use only unleaded gasoline. The

use of leaded gasoline will cause se-

vere damage to the engine internal

parts such as valves, piston rings,

exhaust system, etc.

1. Fuel tank filler tube

2. Fuel level

Recommended fuel:

UNLEADED GASOLINE ONLY

Fuel tank capacity:

Total amount:

15 L (3.3 Imp gal, 4.0 US gal)

Reserve amount:

3 L (0.7 Imp gal, 0.8 US gal)

u5gk12.book Page 7 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-8

Your Yamaha 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 contain-

ing methanol. Gasohol containing

ethanol can be used if the ethanol con-

tent does not exceed 10%. Gasohol

containing methanol is not recom-

mended by Yamaha because it can

cause damage to the fuel system or ve-

hicle performance problems.

EAU00211

Starter (choke) lever

Starting a cold engine requires a richer

air-fuel mixture, which is supplied by

the starter (choke).

Move the lever in direction a to turn on

the starter (choke).

Move the lever in direction b to turn off

the starter (choke).

1. Starter (choke) lever

u5gk12.book Page 8 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-9

EAU03342

Steering lock

To lock the steering

1. Turn the handlebar all the way to

the right.

2. Open the steering lock cover, and

then insert the steering lock key.

3. Turn the key 1/8 turn counter-

clockwise, push it in while turning

the handlebar slightly to the left,

and then turn the key 1/8 turn

clockwise.

4. Check that the steering is locked,

remove the key, and then close

the lock cover.

To unlock the steering

1. Open the steering lock cover, and

then insert the steering lock key.

2. Push the key in, turn it 1/8 turn

counterclockwise so that it moves

out, and then release it.

3. Remove the key, and then close

the lock cover.

EAU03413

Rider seat

To remove the rider seat

1. Release the rider seat backrest by

pushing the levers on the left and

right side as shown, and then slide

the backrest forward.

1. Steering lock 1. Lever (× 2)

u5gk12.book Page 9 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-10

2. Remove the bolts and screws, and

then 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.

EAU00260

Helmet holder

To open the helmet holder, insert the

key into the lock, and then turn the key

as shown.

To lock the helmet holder, place it in

the original position, and then remove

the key.

EW000030

WARNING

Never ride with a helmet attached to

the helmet holder, since the helmet

may hit objects, causing loss of

control and possibly an accident.

1. Bolt (× 2)

2. Screw (× 2)

1. Projection

2. Seat holder

1. Helmet holder

2. Unlock.

u5gk12.book Page 10 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-11

EAU03414

Adjusting the front fork

This front fork is equipped with air

valves for adjusting the spring rate.

EW000035

WARNING

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 motorcycle on the centerstand.

NOTE:

When checking and adjusting the air

pressure, there should be no weight on

the front end of the motorcycle.

2. Remove the air valve cap from

each fork leg.

3. Check the air pressure in each

fork leg with an air pressure

gauge.

NOTE:

An optional air pressure gauge is avail-

able at a Yamaha dealer.

4. To increase the spring rate and

thereby harden the suspension,

increase the air pressure with an

air pump or compressed air. To

decrease the spring rate and

thereby soften the suspension, de-

crease the air pressure by pushing

each valve stem down.

1. Air valve cap

2. Air valve

1. Air pressure gauge

u5gk12.book Page 11 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-12

EC000012

CAUTION:

Never exceed the maximum air pres-

sure, otherwise the front fork oil

seals may become damaged.

EWA00037

WARNING

There must be no difference in air

pressure between the left and right

fork legs, otherwise poor handling

and loss of stability may result.

5. Securely install the air valve caps.

EAU01657

Adjusting the shock absorber

assemblies

Both shock absorber assemblies are

equipped with a spring preload adjust-

ing ring and a damping force adjusting

knob.

EC000015

CAUTION:

Never attempt to turn an adjusting

mechanism beyond the maximum

or minimum settings.

EW000040

WARNING

Always adjust both shock absorber

assemblies equally, otherwise poor

handling and loss of stability may

result.

Spring rate:

Minimum/standard (soft):

Air pressure =

40 kPa (0.4 kgf/cm2, 5.7 psi)

Maximum (hard):

Air pressure =

100 kPa (1.0 kgf/cm2, 14 psi)

1. Shock absorber assembly (× 2)

u5gk12.book Page 12 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-13

Spring preload

To increase the spring preload and

thereby harden the suspension, turn

the adjusting ring on each shock ab-

sorber assembly in direction a. To de-

crease the spring preload and thereby

soften the suspension, turn the adjust-

ing ring on each shock absorber as-

sembly in direction b.

NOTE:

●Align the bottom edge of the ad-

justing ring with the appropriate

setting on the shock absorber.

●Use the special wrench included in

the owner’s tool kit to make this

adjustment.

Damping force

To increase the damping force and

thereby harden the damping, turn the

adjusting knob on each shock absorber

assembly in direction a. To decrease

the damping force and thereby soften

the damping, turn the adjusting knob

on each shock absorber assembly in

direction b.

NOTE:

Align the appropriate setting on the ad-

justing knob with the position indicator

on the shock absorber.

Spring preload:

Minimum (soft): 1

Standard: 1

Maximum (hard): 5

1. Damping force adjusting knob

2. Position indicator

u5gk12.book Page 13 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-14

Damping force:

Minimum (soft): 1

Standard: 1

Maximum (hard): 4

u5gk12.book Page 14 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-15

EAU01658

Matching the front and rear suspension settings

Use this table as a guide to match the suspension and damping adjustments of the front fork and shock absorber assembly

according to various load conditions.

CI-06E

EC000015

CAUTION:

Never attempt to turn an adjusting mechanism beyond the maximum or minimum settings.

Load condition Front fork adjustment Shock absorber assembly adjustment

Spring preload (air pressure) Spring preload Damping force

Rider only

40–60 kPa

0.4–0.6 kgf/cm2

5.7–8.5 psi

1–21–2

With passenger or with

accessories and equipment

40–100 kPa

0.4–1.0 kgf/cm2

5.7–14 psi

3–52–4

With passenger,

accessories and equipment

40–100 kPa

0.4–1.0 kgf/cm2

5.7–14 psi

u5gk12.book Page 15 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-16

EAU00327

V-Boost

The V-Boost is a vital part of the engine

and requires very sophisticated adjust-

ment. Adjustment should be left to a

Yamaha dealer who has the profes-

sional knowledge and experience to do

so.

EC000025

CAUTION:

The V-Boost was set at the Yamaha

factory after many tests. If the set-

tings are changed by someone with-

out sufficient technical knowledge,

poor engine performance and dam-

age may result.

The V-Boost operation can be heard

when the main switch is turned on.

EC000026

CAUTION:

If the V-Boost does not operate, ask

a Yamaha dealer to inspect it.

u5gk12.book Page 16 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-17

EAU00330

Sidestand

The sidestand is located on the left side

of the frame. Raise the sidestand or

lower it with your foot while holding the

motorcycle 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.)

EW000044

WARNING

The motorcycle must not be ridden

with the sidestand down, or if the

sidestand cannot be properly

moved up (or does not stay up), oth-

erwise the sidestand could contact

the ground and distract the opera-

tor, resulting in a possible loss of

control. Yamaha’s ignition circuit

cut-off system has been designed to

assist the operator in fulfilling the

responsibility of raising the side-

stand before starting off. Therefore,

check this system regularly as de-

scribed below and have a Yamaha

dealer repair it if it does not function

properly.

EAU03741

Ignition circuit cut-off system

The ignition circuit cut-off system (com-

prising the sidestand switch, clutch

switch and neutral switch) has the fol-

lowing functions.

●It prevents starting when the trans-

mission is in gear and the side-

stand is up, but the clutch lever is

not pulled.

●It prevents starting when the trans-

mission is in gear and the clutch

lever is pulled, but the sidestand is

still down.

●It cuts the running engine when

the transmission is in gear and the

sidestand is moved down.

Periodically check the operation of the

ignition circuit cut-off system according

to the following procedure.

EW000046

WARNING

●The vehicle must be placed on

the centerstand during this in-

spection.

●If a malfunction is noted, have a

Yamaha dealer check the sys-

tem before riding.

u5gk12.book Page 17 Wednesday, June 13, 2001 8:55 AM

INSTRUMENT AND CONTROL FUNCTIONS

3-18

CD-01E

With the engine turned off:

1. Move the sidestand down.

2. Make sure that the engine stop switch is set to “RUN”.

3. Turn the key to “ON”.

4. Shift the transmission into the neutral position.

5. Push the start switch.

Does the engine start? The neutral switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

With the engine still running:

6. Move the sidestand up.

7. Keep the clutch lever pulled.

8. Shift the transmission into gear.

9. Move the sidestand down.

Does the engine stall?

After the engine has stalled:

10. Move the sidestand up.

11. Keep the clutch lever pulled.

12. Push the start switch.

Does the engine start?

The sidestand switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

The clutch switch may be defective.

The motorcycle should not be ridden until

checked by a Yamaha dealer.

NOTE:

This check is most reliable if performed with

a warmed-up engine.

YES

YES NO

The system is OK. The motorcycle can be ridden.

YES NO

u5gk12.book Page 18 Wednesday, June 13, 2001 8:55 AM

PRE-OPERATION CHECKS

Pre-operation check list ..................................................................... 4-1

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

4-1

EAU01114

PRE-OPERATION CHECKS

The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,

even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss

of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-

tion, to check the following points before each ride.

EAU03439

Pre-operation check list

CO-01E

ITEM CHECKS PAGE

Fuel

•Check fuel level in fuel tank.

•Refuel if necessary.

•Check fuel line for leakage.

3-7–3-8

Engine oil

•Check oil level in engine.

•If necessary, add recommended oil to specified level.

•Check vehicle for oil leakage.

6-11–6-12

Final gear oil •Check vehicle for oil leakage. 6-15

Coolant

•Check coolant level in reservoir.

•If necessary, add recommended coolant to specified level.

•Check cooling system for leakage.

6-16–6-17

Front brake

•Check operation.

•If soft or spongy, have Yamaha dealer bleed hydraulic system.

•Check lever free play.

•Adjust if necessary.

•Check fluid level in reservoir.

•If necessary, add recommended brake fluid to specified level.

•Check hydraulic system for leakage.

6-27–6-30

Rear brake

•Check operation.

•If soft or spongy, have Yamaha dealer bleed hydraulic system.

•Check fluid level in reservoir.

•If necessary, add recommended brake fluid to specified level.

•Check hydraulic system for leakage.

6-27–6-30

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

PRE-OPERATION CHECKS

4-2

Clutch

•Check operation.

•If soft or spongy, have Yamaha dealer bleed hydraulic system.

•Check fluid level in reservoir.

•If necessary, add recommended fluid to specified level.

•Check hydraulic system for leakage.

6-26, 6-29–6-30

Throttle grip

•Make sure that operation is smooth.

•Lubricate throttle grip, housing and cables if necessary.

•Check free play.

•If necessary, have Yamaha dealer make adjustment.

6-22, 6-31

Control cables •Make sure that operation is smooth.

•Lubricate if necessary. 6-30

Wheels and tires

•Check for damage.

•Check tire condition and tread depth.

•Check air pressure.

•Correct if necessary.

6-23–6-25

Brake and shift pedals •Make sure that operation is smooth.

•Lubricate pedal pivoting points if necessary. 6-31

Brake and clutch levers •Make sure that operation is smooth.

•Lubricate lever pivoting points if necessary. 6-32

Centerstand, sidestand •Make sure that operation is smooth.

•Lubricate pivots if necessary. 6-33

Chassis fasteners •Make sure that all nuts, bolts and screws are properly tightened.

•Tighten if necessary. —

Instruments, lights, signals

and switches

•Check operation.

•Correct if necessary. —

Sidestand switch •Check operation of ignition circuit cut-off system.

•If system is defective, have Yamaha dealer check vehicle. 3-17

Battery •Check fluid level.

•Fill with distilled water if necessary. 6-36–6-38

ITEM CHECKS PAGE

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

PRE-OPERATION CHECKS

4-3

NOTE:

Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very

short time; and the added safety it assures is more than worth the time involved.

EWA00033

WARNING

If any item in the Pre-operation check list is not working properly, have it inspected and repaired before operating

the motorcycle.

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

OPERATION AND IMPORTANT RIDING POINTS

Starting and warming up a cold engine ............................................. 5-1

Starting a warm engine ..................................................................... 5-3

Shifting .............................................................................................. 5-3

Engine break-in ................................................................................. 5-5

Parking .............................................................................................. 5-6

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

5-1

EAU00372

OPERATION AND IMPORTANT RIDING POINTS

EAU00373

WARNING

●Become thoroughly familiar

with all operating controls and

their functions before riding.

Consult a Yamaha dealer re-

garding any control or function

that you do not thoroughly un-

derstand.

●Never start the engine or oper-

ate it in a closed area for any

length of time. Exhaust fumes

are poisonous, and inhaling

them can cause loss of con-

sciousness and death within a

short time. Always make sure

that there is adequate ventila-

tion.

●Before starting out, make sure

that the sidestand is up. If the

sidestand is not raised com-

pletely, it could contact the

ground and distract the opera-

tor, resulting in a possible loss

of control.

EAU00376

CAUTION:

●Make sure not to store personal

items near the air cleaner in-

take, otherwise air intake will be

blocked and performance will

suffer.

●Make sure not to put anything

near the battery and its termi-

nals, otherwise electrical failure

and acid corrosion may result.

EAU01164

Starting and warming up a

cold engine

In order for the ignition circuit cut-off

system to enable starting, one of the

following conditions must be met:

●The transmission is in the neutral

position.

●The transmission is in gear with

the clutch lever pulled and the

sidestand up.

EW000054

WARNING

●Before starting the engine,

check the function of the igni-

tion circuit cut-off system ac-

cording to the procedure

described on page 3-18.

●Never ride with the sidestand

down.

1. Turn the key to “ON” and make

sure that the engine stop switch is

set to “RUN”.

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

OPERATION AND IMPORTANT RIDING POINTS

5-2

EC000035

CAUTION:

If the fuel level warning light comes

on, check the fuel level, and, if nec-

essary, refuel as soon as possible.

2. Shift the transmission into the neu-

tral position.

NOTE:

When the transmission is in the neutral

position, the neutral indicator light

should be on, otherwise have a

Yamaha dealer check the electrical cir-

cuit.

3. Turn the starter (choke) on and

completely close the throttle. (See

page 3-8 for starter (choke) opera-

tion.)

4. Start the engine by pushing the

start switch.

NOTE:

If the engine fails to start, release the

start switch, wait a few seconds, and

then try again. Each starting attempt

should be as short as possible to pre-

serve the battery. Do not crank the en-

gine more than 10 seconds on any one

attempt.

EC000038

CAUTION:

●The oil level warning light and

fuel level warning light should

come on when the start switch

is pushed, and they should go

off when the start switch is re-

leased.

●If the oil level warning light flick-

ers or remains on after starting,

immediately stop the engine,

and then check the engine oil

level and the vehicle for oil leak-

age. If necessary, add engine

oil, and then check the warning

light again. If the warning light

does not come on when push-

ing the start switch, or if it does

not go off after starting with suf-

ficient engine oil, have a

Yamaha dealer check the elec-

trical circuit.

●If the fuel level warning light re-

mains on after starting, stop the

engine, and then check the fuel

level. If necessary, refuel as

soon as possible, and then

check the warning light again. If

the warning light does not come

on when 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) lever back halfway.

ECA00055

CAUTION:

For maximum engine life, always

warm the engine up before starting

off. Never accelerate hard when the

engine is cold!

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

OPERATION AND IMPORTANT RIDING POINTS

5-3

6. When the engine is warm, turn the

starter (choke) off.

NOTE:

The engine is warm when it responds

normally to the throttle with the starter

(choke) turned off. To avoid the possi-

bility of excessive exhaust emissions,

never leave the starter (choke) on long-

er than necessary. The time necessary

for starter (choke) use depends upon

the ambient temperature. Tempera-

tures above 10 °C (50 °F) require about

7 seconds of starter (choke) use and

temperatures below 10 °C (50 °F) re-

quire about 35 seconds with the starter

(choke) turned on, then about 2.5 min-

utes with the starter (choke) in the half-

way position.

EAU01258

Starting a warm engine

Follow the same procedure as for start-

ing a cold engine with the exception

that the starter (choke) is not required

when the engine is warm.

EAU00423

Shifting

Shifting gears lets you control the

amount of engine power available for

starting off, accelerating, climbing hills,

etc.

The gear positions are shown in the il-

lustration.

NOTE:

To shift the transmission into the neu-

tral position, press the shift pedal down

repeatedly until it reaches the end of its

travel, and then slightly raise it.

1. Shift pedal

N. Neutral position

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

OPERATION AND IMPORTANT RIDING POINTS

5-4

EC000048

CAUTION:

●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 dam-

aging the engine, transmission,

and drive train, which are not

designed to withstand the

shock of forced shifting.

EAU02988

To start out and accelerate

1. Pull the clutch lever to disengage

the clutch.

2. Shift the transmission into first

gear. The neutral indicator light

should go out.

3. Open the throttle gradually, and at

the same time, release the clutch

lever slowly.

4. At the recommended shift points

shown in the table on page 5-5,

close the throttle, and at the same

time, quickly pull the clutch lever

in.

5. Shift the transmission into second

gear. (Make sure not to shift the

transmission into the neutral posi-

tion.)

6. Open the throttle part way and

gradually release the clutch lever.

7. Follow the same procedure when

shifting to the next higher gear.

NOTE:

Always shift gears at the recommend-

ed shift points.

EAU00427

To decelerate

1. Apply both the front and the rear

brakes to slow the motorcycle.

2. Shift the transmission into first

gear when the motorcycle reaches

20 km/h (12.5 mi/h). If the engine

is about to stall or runs very rough-

ly, pull the clutch lever in and use

the brakes to stop the motorcycle.

3. Shift the transmission into the neu-

tral position when the motorcycle

is almost completely stopped. The

neutral indicator light should come

on.

u5gk12.book Page 4 Wednesday, June 13, 2001 8:55 AM

OPERATION AND IMPORTANT RIDING POINTS

5-5

EAU02974

Recommended shift points

The recommended shift points during

acceleration and deceleration are

shown in the table below.

CF-04E

EAU01128

Engine break-in

There is never a more important period

in the life of your engine than the period

between 0 and 1,600 km (1,000 mi).

For this reason, you should read the

following material carefully.

Since the engine is brand new, do not

put an excessive load on it for the first

1,600 km (1,000 mi). The various parts

in the engine wear and polish them-

selves to the correct operating clear-

ances. During this period, prolonged

full-throttle operation or any condition

that might result in engine overheating

must be avoided.

EAU04032*

0–1,000 km (0–600 mi)

Avoid prolonged operation above

4,500 r/min.

1,000–1,600 km (600–1,000 mi)

Avoid prolonged operation above

5,500 r/min.

EC000056*

CAUTION:

After 1,000 km (600 mi) of operation,

the engine oil and final gear oil must

be changed, and the oil filter car-

tridge replaced.

1,600 km (1,000 mi) and beyond

The vehicle can now be operated nor-

mally.

EC000053

CAUTION:

●Keep the engine speed out of

the tachometer red zone.

●If any engine trouble should oc-

cur during the engine break-in

period, immediately have a

Yamaha dealer check the vehicle.

Acceleration

shift point

km/h (mi/h)

Deceleration

shift point

km/h (mi/h)

1st →2nd

2nd →3rd

3rd →4th

4th →5th

16 (10.0)

24 (15.0)

32 (20.0)

40 (25.0)

20 (12.5)

u5gk12.book Page 5 Wednesday, June 13, 2001 8:55 AM

OPERATION AND IMPORTANT RIDING POINTS

5-6

EAU00460

Parking

When parking, stop the engine, and

then remove the key from the main

switch.

EW000058

WARNING

●Since the engine and exhaust

system can become very hot,

park in a place where pedestri-

ans or children are not likely to

touch them.

●Do not park on a slope or on

soft ground, otherwise the

motorcycle may overturn.

u5gk12.book Page 6 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

Periodic maintenance ..........................................6-1

Owner’s tool kit ....................................................6-1

Periodic maintenance chart for emission

control system ...................................................6-3

General maintenance and lubrication chart .........6-5

Removing and installing the cowling and

panels ................................................................6-8

Checking the spark plugs ....................................6-9

Canister (for California only) ..............................6-11

Engine oil and oil filter cartridge ........................6-11

Final gear oil ......................................................6-15

Coolant ..............................................................6-16

Cleaning the air filter element ............................6-21

Adjusting the carburetors ...................................6-22

Adjusting the throttle cable free play ..................6-22

Adjusting the valve clearance ............................6-22

Tires ...................................................................6-23

Cast wheels .......................................................6-25

Accessories and replacement parts ..................6-25

Clutch lever free play .........................................6-26

Adjusting the brake lever free play .....................6-27

Adjusting the brake pedal position .....................6-27

Adjusting the rear brake light switch ..................6-28

Checking the front and rear brake pads .............6-28

Checking the brake and clutch fluid levels ........ 6-29

Changing the brake and clutch fluids ................ 6-30

Checking and lubricating the cables ................. 6-30

Checking and lubricating the throttle grip and

cable ............................................................... 6-31

Checking and lubricating the brake and

shift pedals ...................................................... 6-31

Checking and lubricating the brake and

clutch levers .................................................... 6-32

Checking and lubricating the centerstand and

sidestand ......................................................... 6-33

Lubricating the rear suspension ........................ 6-33

Checking the front fork ...................................... 6-34

Checking the steering ....................................... 6-35

Checking the wheel bearings ............................ 6-35

Battery ............................................................... 6-36

Replacing the fuses .......................................... 6-39

Replacing the headlight bulb ............................. 6-41

Replacing a turn signal light bulb or

the tail/brake light bulb .................................... 6-42

Front wheel ....................................................... 6-43

Rear wheel ........................................................ 6-45

Troubleshooting ................................................. 6-47

Troubleshooting charts ...................................... 6-48

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

6-1

EAU00462

PERIODIC MAINTENANCE AND MINOR REPAIR

EAU01790

Safety is an obligation of the owner.

Periodic inspection, adjustment and lu-

brication will keep your vehicle in the

safest and most efficient condition pos-

sible. The most important points of

motorcycle inspection, adjustment, and

lubrication are explained on the follow-

ing pages.

Maintenance, replacement, or repair

of the emission control devices and

systems may be performed by any

repair establishment or individual

that is certified (if applicable).

EW000060

WARNING

If you are not familiar with motor-

cycle maintenance work, have a

Yamaha dealer do it for you.

EAU00467

PERIODIC MAINTENANCE

PROPER PERIODIC MAINTENANCE

OF YOUR MOTORCYCLE IS IMPOR-

TANT IN ORDER TO ENJOY LONG,

PLEASURABLE SERVICE. ESPE-

CIALLY IMPORTANT ARE THE

MAINTENANCE SERVICES RELAT-

ED TO EMISSIONS CONTROL.

THESE CONTROLS NOT ONLY

FUNCTION TO ENSURE CLEANER

AIR, BUT ARE ALSO VITAL TO

PROPER ENGINE OPERATION AND

MAXIMUM PERFORMANCE. IN THE

FOLLOWING PERIODIC MAINTE-

NANCE CHARTS, THE SERVICES

RELATED TO EMISSIONS CON-

TROL ARE GROUPED SEPARATE-

LY. THESE SERVICES REQUIRE

SPECIALIZED DATA, KNOWLEDGE,

AND EQUIPMENT. YAMAHA DEAL-

ERS ARE TRAINED AND EQUIPPED

TO PERFORM THESE PARTICULAR

SERVICES.

EAU01659

Owner’s tool kit

The tool kit is located inside the storage

compartment behind the rider seat

backrest. (See page 3-9 for an expla-

nation on moving the rider seat back-

rest forward and back.)

1. Owner’s tool kit

2. Rider seat backrest

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-2

The service information included in this

manual and the tools provided in the

owner’s tool kit are intended to assist

you in the performance of preventive

maintenance and minor repairs. How-

ever, additional tools such as a torque

wrench may be necessary to perform

certain maintenance work correctly.

NOTE:

If you do not have the tools or experi-

ence required for a particular job, have

a Yamaha dealer perform it for you.

EW000063

WARNING

Modifications not approved by

Yamaha may cause loss of perfor-

mance and render the vehicle un-

safe for use. Consult a Yamaha

dealer before attempting any

changes.

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-3

EAU00471

Periodic maintenance chart for emission control system

No. ITEM ROUTINE

INITIAL ODOMETER READINGS

600 mi

(1,000 km)

1 month

4,000mi

(7,000 km)

6 months

8,000 mi

(13,000 km)

12 months

12,000 mi

(19,000 km)

18 months

16,000 mi

(25,000 km)

24 months

20,000 mi

(31,000 km)

30 months

1*Valve clearance •Check and adjust valve clearance

when engine is cold. Every 30,000 mi (42,000 km) or 42 months

2Spark plugs

•Check condition.

•Adjust gap and clean.

•Replace every 8,000 mi (13,000 km)

or 12 months.

√Replace. √Replace. √

3*Crankcase

ventilation system

•Check ventilation hose for cracks or

damage.

•Replace if necessary.

√√√√√

4*Fuel line

•Check fuel hoses for cracks or

damage.

•Replace if necessary.

√√√√√

5*Fuel filter

•Replace initial 20,000 mi (31,000 km)

or 30 months and thereafter every

20,000 mi (31,000 km) or 30 months.

Replace.

6*Exhaust system

•Check for leakage.

•Retighten if necessary.

•Replace gasket(s) if necessary.

√√√√√

7*Carburetor

synchronization •Adjust synchronization of carburetors. √√√√√√

8*Idle speed •Check and adjust engine idle speed.

•Adjust cable free play. √√√√√

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-4

*Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

Evaporative

emission control

system (For

California only)

•Check control system for damage.

•Replace if necessary. √√

No. ITEM ROUTINE

INITIAL ODOMETER READINGS

600 mi

(1,000 km)

1 month

4,000mi

(7,000 km)

6 months

8,000 mi

(13,000 km)

12 months

12,000 mi

(19,000 km)

18 months

16,000 mi

(25,000 km)

24 months

20,000 mi

(31,000 km)

30 months

u5gk12.book Page 4 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-5

EAU00472

General maintenance and lubrication chart

No. ITEM ROUTINE TYPE

INITIAL ODOMETER READINGS

600 mi

(1,000 km)

1 month

4,000 mi

(7,000 km)

6 months

8,000 mi

(13,000 km)

12 months

12,000 mi

(19,000 km)

18 months

16,000 mi

(25,000 km)

24 months

20,000 mi

(31,000 km)

30 months

1 Engine oil

•Replace (warm up

engine before

draining).

See page 8-1. √√√√√√

2Engine oil filter

cartridge •Replace. –√√√

3*Air filter element

•Clean with

compressed air.

•Replace if necessary.

–√√√√√

4*Cooling system

•Check hose for cracks

or damage, replace if

necessary.

–√√√√√

•Replace coolant every

24 months.

Ethylene glycol

antifreeze coolant Replace.

5*Brake system

•Adjust free play.

•Replace pads if

necessary.

–√√√√√√

6*Clutch

•Check operation and

fluid leakage. (See

NOTE page 6-7.)

•Correct if necessary.

–√√√√√√

7 Final gear oil

•Check oil level and

leakage.

•Replace every

16,000 mi (25,000 km)

or 24 months.

Hypoid gear oil SAE 80

(API GL-4) Replace. √√√Replace. √

8Control and meter

cable

•Apply chain lube

thoroughly.

Yamaha Chain and

Cable Lube or engine oil

SAE 10W-30

√√√√√√

u5gk12.book Page 5 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-6

9*Swingarm pivot

bearing

•Check bearing

assembly for

looseness.

•Moderately repack

every 16,000 mi

(25,000 km).

Lithium-soap-based

grease √Repack.

10 Brake and clutch

lever pivot shaft

•Apply lithium-soap-

based grease

(all-purpose grease)

lightly.

Lithium-soap-based

grease

(all-purpose grease)

√√√√√

11 Brake pedal and shift

pedal shaft

•Lubricate.

•Apply lithium-soap-

based grease

(all-purpose grease)

lightly.

Lithium-soap-based

grease

(all-purpose grease)

√√√√√

12 *Center/sidestand

pivots

•Check operation and

lubricate.

•Apply lithium-soap-

based grease

(all-purpose grease)

lightly.

Lithium-soap-based

grease

(all-purpose grease)

√√√√√

13 *Front fork •Check operation and

leakage. –√√√√√

14 *Steering bearings

•Check bearing

assembly for

looseness.

•Moderately repack

every 16,000 mi

(25,000 km).

Lithium-soap-based

grease √√√

Repack. √

15 *Wheel bearings •Check bearings for

smooth rotation. –√√√√√

16 *Battery

•Check specific gravity

and breather pipe for

proper operation.

–√√√√√

No. ITEM ROUTINE TYPE

INITIAL ODOMETER READINGS

600 mi

(1,000 km)

1 month

4,000 mi

(7,000 km)

6 months

8,000 mi

(13,000 km)

12 months

12,000 mi

(19,000 km)

18 months

16,000 mi

(25,000 km)

24 months

20,000 mi

(31,000 km)

30 months

u5gk12.book Page 6 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-7

*Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

EAU03907

NOTE:

From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.

EAU03892

NOTE:

●The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

●Hydraulic brake and clutch 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 hoses every four years or if cracked or damaged.

17 *Sidestand switch •Check and clean or

replace if necessary. –√√√√√√

No. ITEM ROUTINE TYPE

INITIAL ODOMETER READINGS

600 mi

(1,000 km)

1 month

4,000 mi

(7,000 km)

6 months

8,000 mi

(13,000 km)

12 months

12,000 mi

(19,000 km)

18 months

16,000 mi

(25,000 km)

24 months

20,000 mi

(31,000 km)

30 months

u5gk12.book Page 7 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-8

EAU03516

Removing and installing the

cowling and panels

The cowling and panels shown above

need to be removed to perform some

of the maintenance jobs described in

this chapter. Refer to this section each

time the cowling or a panel needs to be

removed and installed.

EAU03415

Cowling A

To remove the cowling

1. Insert the key into the lock, and

then turn it clockwise.

2. Pull the cowling off as shown.

To install the cowling

1. Align the holders under the cowl-

ing with the projections on the

frame.

2. Push down on the rear of the cowl-

ing until it locks in place.

3. Remove the key from the lock.

1. Cowling A

2. Panel A

3. Panel B

1. Unlock. 1. Holder (× 2)

2. Projection (× 2)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-9

EAU03340

Panel A

To remove the panel

1. Remove cowling A. (See page 6-8

for cowling removal and installa-

tion procedures.)

2. Remove the screws, and then take

the panel off.

To install the panel

1. Place the panel in the original po-

sition, and then install the screws.

2. Install the cowling.

EAU01315

Panel B

To remove the panel

Remove the screws, and then take the

panel off.

To install the panel

Place the panel in the original position,

and then install the screws.

EAU03329

Checking the spark plugs

The spark plugs are important engine

components, which are easy to check.

Since heat and deposits will cause any

spark plug to slowly erode, the spark

plugs should be removed and checked

in accordance with the periodic mainte-

nance and lubrication chart. In addition,

the condition of the spark plugs can re-

veal the condition of the engine.

To remove a spark plug

1. Remove the spark plug cap.

1. Screw (× 2) 1. Screw (× 2) 1. Spark plug cap

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-10

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

motorcycle is ridden normally).

2. Check that all spark plugs installed

in the engine have the same color.

NOTE:

If any spark plug shows a distinctly dif-

ferent color, the engine could be defec-

tive. Do not attempt to diagnose such

problems yourself. Instead, have a

Yamaha dealer check the motorcycle.

3. Check each spark plug for elec-

trode erosion and excessive car-

bon or other deposits, and replace

it if necessary. To install a spark plug

1. Measure the spark plug gap with a

wire thickness gauge and, if nec-

essary, adjust the gap to specifica-

tion.

2. Clean the surface of the spark

plug gasket and its mating sur-

face, and then wipe off any grime

from the spark plug threads.

3. Install the spark plug with the

spark plug wrench, and then tight-

en it to the specified torque.

1. Spark plug wrench

Specified spark plug:

DPR8EA-9/NGK or

X24EPR-U9/DENSO

a. Spark plug gap

Spark plug gap:

0.8–0.9 mm (0.03–0.04 in)

u5gk12.book Page 10 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-11

NOTE:

If a torque wrench is 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.

EAU01796

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.

●Check each hose and canister for

cracks or damage. Replace if

damaged.

●Make sure the vent hose is not

blocked. Clean it if necessary.

EAU04185

Engine oil and oil filter

cartridge

The engine oil level should be checked

before each ride. In addition, the oil

must be changed and the oil filter car-

tridge replaced at the intervals speci-

fied in the periodic maintenance and

lubrication chart.

To check the engine oil level

1. Place the motorcycle on the cen-

terstand.

NOTE:

Make sure that the motorcycle is posi-

tioned straight up when checking the oil

level. A slight tilt to the side can result in

a false reading.

2. Start the engine, warm it up for

several minutes, and then turn it

off.

Tightening torque:

Spark plug:

18 Nm (1.8 m·kgf, 13 ft·lb)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-12

3. Wait a few minutes 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 replace-

ment)

1. Start the engine, warm it up for

several minutes, and then turn it

off.

2. Place an oil pan under the engine

to collect the used oil.

3. Remove the engine oil filler cap

and drain bolt to drain the oil from

the crankcase.

NOTE:

Skip steps 4–6 if the oil filter cartridge is

not being replaced.

1. Engine oil level check window

2. Maximum level mark

3. Minimum level mark

1. Engine oil filler cap 1. Engine oil drain bolt

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-13

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.

NOTE:

Make sure that the O-ring is properly

seated.

6. Install the new oil filter cartridge

with an oil filter wrench, and then

tighten it to the specified torque

with a torque wrench.

7. Install the engine oil drain bolt, and

then tighten it to the specified

torque.

1. Oil filter cartridge

2. Oil filter wrench

1. O-ring 1. Torque wrench

Tightening torque:

Oil filter cartridge:

17 Nm (1.7 m·kgf, 12 ft·lb)

Tightening torque:

Engine oil drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lb)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-14

8. Add the specified amount of the

recommended engine oil, and

then install and tighten the oil filler

cap.

EC000072

CAUTION:

●In order to prevent clutch slip-

page (since the engine oil also

lubricates the clutch), do not

mix any chemical additives with

the oil or use oils of a higher

grade than “CD”. 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,

immediately turn the engine off

and check for the cause.

NOTE:

After the engine is started, the engine

oil level warning light should go off if the

oil level is sufficient.

EC000067

CAUTION:

If the oil level warning light flickers

or remains on, immediately turn the

engine off and have a Yamaha deal-

er check the vehicle.

10. Turn the engine off, and then

check the oil level and correct it if

necessary.

Recommended engine oil:

See page 8-1.

Oil quantity:

Without oil filter cartridge

replacement:

3.2 L (2.8 Imp qt, 3.4 US qt)

With oil filter cartridge

replacement:

3.4 L (3.0 Imp qt, 3.6 US qt)

Total amount (dry engine):

4.0 L (3.5 Imp qt, 4.2 US qt)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-15

EAU03681

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 motorcycle. In

addition, the final gear oil must be

changed as follows at the intervals

specified in the periodic maintenance

and lubrication chart.

EW000066

WARNING

●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 motorcycle on the cen-

terstand.

NOTE:

●The final gear oil level must be

checked on a cold engine.

●Make sure that the motorcycle is

positioned straight up when check-

ing the oil level. A slight tilt to the

side can result in a false reading.

2. Remove the oil filler bolt, and then

check the oil level in the final gear

case.

NOTE:

The oil level should be at the brim of

the filler hole.

3. If the oil is below the brim of the fill-

er hole, add sufficient oil of the rec-

ommended type to raise it to the

correct level.

To change the final gear oil

1. Place an oil pan under the final

gear case to collect the used oil.

2. Remove the oil filler bolt and drain

bolt to drain the oil from the final

gear case.

3. Install the final gear oil drain bolt,

and then tighten it to the specified

torque.

4. Add the recommended final gear

oil to the brim of the filler hole.

NOTE:

GL4 is a quality rating. Hypoid gear oils

rated GL5 or GL6 may also be used.

5. Install and tighten the filler bolt.

6. Check the final gear case for oil

leakage. If oil is leaking, check for

the cause.

1. Final gear oil filler bolt

2. Correct oil level

3. Final gear oil drain bolt

Tightening torque:

Final gear oil drain bolt:

23 Nm (2.3 m·kgf, 17 ft·lb)

Recommended final gear oil:

Hypoid gear oil SAE 80 (API GL4)

or multi-grade hypoid gear oil

SAE 80W-90

Oil quantity:

0.2 L (0.18 Imp qt, 0.21 US qt)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-16

EAU04186

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.

To check the coolant level

1. Place the motorcycle on a level

surface and hold it in an upright

position.

2. Remove cowling A. (See page 6-8

for cowling removal and installa-

tion procedures.)

NOTE:

●The coolant level must be checked

on a cold engine since the level

varies with engine temperature.

●Make sure that the motorcycle is

positioned straight up when

checking the coolant level. A slight

tilt to the side can result in a false

reading.

3. Check the coolant level in the

coolant reservoir.

NOTE:

The coolant should be between the

minimum and maximum level marks.

4. If the coolant is at or below the

minimum level mark, remove the

coolant reservoir cap and add

coolant to the maximum level

mark.

5. Install the coolant reservoir cap

and the cowling.

1. Maximum level mark

2. Minimum level mark

Coolant reservoir capacity:

0.3 L (0.26 Imp, 0.32 US qt)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-17

EC000080

CAUTION:

●If coolant is not available, use

distilled water or soft tap water

instead. Do not use hard water

or salt water since it is harmful

to the engine.

●If water has been used instead

of coolant, replace it with cool-

ant as soon as possible, other-

wise the engine may not be

sufficiently cooled and the cool-

ing system will not be protected

against frost and corrosion.

●If water has been added to the

coolant, have a Yamaha dealer

check the antifreeze content of

the coolant as soon as possible,

otherwise the effectiveness of

the coolant will be reduced.

EW000067

WARNING

Never attempt to remove the radia-

tor cap when the engine is hot.

NOTE:

●The radiator fan is automatically

switched on or off according to the

coolant temperature in the radia-

tor.

●If the engine overheats, see

page 6-49 for further instructions.

EAU03417

To change the coolant

1. Place the motorcycle on a level

surface and let the engine cool if

necessary.

2. Remove cowling A and panel A.

(See pages 6-8 and 6-9 for cowl-

ing and panel removal and instal-

lation procedures.)

3. Place a container under the en-

gine to collect the used coolant.

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-18

4. Remove the radiator cap.

EW000067

WARNING

Never attempt to remove the radia-

tor cap when the engine is hot.

5. Turn the coolant drain cock to

“ON”.

6. Remove the water pump drain bolt

to drain the water pump housing.

1. Radiator cap 1. Coolant drain cock

2. Position indicator

1. Water pump drain bolt

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-19

7. Remove the cylinder drain plug

covers on the outside of the cylin-

der blocks by removing the

screws.

8. Remove the rubber coolant drain

plugs to drain the coolant from the

engine.

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.

NOTE:

Check the rubber plugs for damage

and replace them if necessary.

12. Turn the coolant drain cock to

“OFF”.

13. Pour the recommended coolant

into the reservoir to the maximum

level, and then install the cap.

14. Pour the recommended coolant

into the radiator until it is full.

1. Screw (× 4) 1. Rubber coolant drain plug (× 4)

Tightening torque:

Water pump drain bolt:

43 Nm (4.3 m·kgf, 31 ft·lb)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-20

EC000080

CAUTION:

●If coolant is not available, use

distilled water or soft tap water

instead. Do not use hard water

or salt water since it is harmful

to the engine.

●If water has been used instead

of coolant, replace it with cool-

ant as soon as possible, other-

wise the engine may not be

sufficiently cooled and the cool-

ing system will not be protected

against frost and corrosion.

●If water has been added to the

coolant, have a Yamaha dealer

check the antifreeze content of

the coolant as soon as possible,

otherwise the effectiveness of

the coolant will be reduced.

15. Install the radiator cap, start the

engine, let it idle for several min-

utes, and then turn it off.

16. Remove the radiator cap to check

the coolant level in the radiator. If

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 leaking, have a Yamaha

dealer check the cooling system.

19. Install the cowling and the panel.

Antifreeze/water mixture ratio:

1:1

Recommended antifreeze:

High-quality ethylene glycol

antifreeze containing corrosion

inhibitors for aluminum engines

Coolant quantity:

Total amount:

3.05 L (2.68 Imp qt, 3.22 US qt)

Coolant reservoir capacity:

0.3 L (0.26 Imp qt, 0.32 US qt)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-21

EAU01662*

Cleaning the air filter element

The air filter element should be cleaned

at the intervals specified in the periodic

maintenance and lubrication chart.

Clean the air filter element more fre-

quently if you are riding in unusually

wet or dusty areas.

1. Remove cowling A. (See page 6-8

for cowling removal and installa-

tion procedures.)

2. Remove the air filter case cover by

removing the screws.

3. Pull the air filter element out.

4. Lightly tap the air filter element to

remove most of the dust and dirt,

and then blow the remaining dirt

out with compressed air as shown.

If the air filter element is damaged,

replace it.

5. Insert the air filter element into the

air filter case.

EC000082*

CAUTION:

●Make sure that the air filter ele-

ment is properly seated in the

air filter case.

●The engine should never be op-

erated without the air filter ele-

ment installed, otherwise the

pistons and/or cylinders may

become excessively worn.

6. Install the air filter case cover by

installing the screws.

7. Install the cowling.

1. Screw (× 6) 1. Air filter element

u5gk12.book Page 21 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-22

EAU00628

Adjusting the carburetors

The carburetors are important parts of

the engine and emission control sys-

tem, which require very sophisticated

adjustment. Therefore, all carburetor

adjustments should be left to a

Yamaha dealer, who has the neces-

sary professional knowledge and expe-

rience.

EAU00635

Adjusting the throttle cable

free play

The throttle cable free play should

measure 3–5 mm (0.12–0.20 in) at the

throttle grip. Periodically check the

throttle cable free play and, if neces-

sary, have a Yamaha dealer adjust it.

EAU00637

Adjusting the valve clearance

The valve clearance changes with use,

resulting in improper air-fuel mixture

and/or engine noise. To prevent this

from occurring, the valve clearance

must be adjusted by a Yamaha dealer

at the intervals specified in the periodic

maintenance and lubrication chart.

a. Throttle cable free play

u5gk12.book Page 22 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-23

EAU03360

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.

EW000082

WARNING

●The tire air pressure must be

checked and adjusted on cold

tires (i.e., when the temperature

of the tires equals the ambient

temperature).

●The tire air pressure must be

adjusted in accordance with the

riding speed and with the total

weight of rider, passenger, car-

go, and accessories approved

for this model.

CE-22E

CE-07E

EW000083

WARNING

Proper loading of your motorcycle

is important for several characteris-

tics of your motorcycle, such as

handling, braking, performance and

safety. Do not carry loosely packed

items that can shift. Securely pack

your heaviest items close to the

center of the motorcycle, and dis-

tribute the weight evenly from side

to side. Properly adjust the suspen-

sion for your load, and check the

condition and pressure of your tires.

NEVER OVERLOAD YOUR MOTOR-

CYCLE. Make sure the total weight

of the cargo, rider, passenger, and

accessories (cowling, saddlebags,

etc. if approved for this model) does

not exceed the maximum load of the

motorcycle. Operation of an over-

loaded motorcycle could cause tire

damage, an accident, or even injury.

Tire air pressure

(measured on cold tires)

Load* Front Rear

Up to 90 kg (198 lb)

225 kPa

(2.25 kgf/cm2,

33 psi)

225 kPa

(2.25 kgf/cm2,

33 psi)

90 kg (198 lb)–

maximum

225 kPa

(2.25 kgf/cm2,

33 psi)

2.50 kPa

(2.50 kgf/cm2,

36 psi)

High-speed riding

225 kPa

(2.25 kgf/cm2,

33 psi)

2.50 kPa

(2.50 kgf/cm2,

36 psi)

Maximum load* 216 kg (476 lb): VMX12

215 kg (474 lb): VMX12C

* Total weight of rider, passenger, cargo and

accessories

u5gk12.book Page 23 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-24

Tire inspection

Always check the tires before operating

the motorcycle. If a tire tread shows

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.

CE-10E

CE-23E

EAU00684

WARNING

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 road

surfaces until they have been

“broken in”. Therefore, it is ad-

visable before doing any high-

speed riding to ride conserva-

tively for approximately 100 km

(60 mi) after installing a new

tire.

●The tires must be warmed up

before a high-speed run.

●Always adjust the tire air pres-

sure according to the operating

conditions.

1. Tire sidewall

2. Tire wear indicator

a. Tire tread depth

FRONT

Manufacturer Size Model

Bridgestone 110/90-18 M/C 61V

110/90-18 61V G525AW

Dunlop 110/90-18 M/C 61V

110/90-18 61V F20

REAR

Manufacturer Size Model

Bridgestone 150/90-15 M/C 74V G526BW

Dunlop 150/90-15 M/C 74V K525

Minimum tire tread depth

(front and rear) 1.0 mm (0.04 in)

u5gk12.book Page 24 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-25

EAU00689

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. A deformed or cracked

wheel must be replaced.

●The wheel should be balanced

whenever either the tire or wheel

has been changed or replaced. An

unbalanced wheel can result in

poor performance, adverse han-

dling characteristics, and a short-

ened tire life.

●Ride at moderate speeds after

changing a tire since the tire sur-

face must first be “broken in” for it

to develop its optimal characteris-

tics.

●After repairing or replacing a tire,

tighten the valve stem nut and

locknut to the specified torques.

EAU00691

Accessories and replacement

parts

EW000098

WARNING

This motorcycle is not designed to

pull a trailer or to be attached to a

sidecar. The accessories or replace-

ment parts you choose for your

motorcycle should be designed spe-

cifically for this model, and they

must be securely mounted to main-

tain the inherent stability of the orig-

inal design. Genuine Yamaha Parts

and Accessories 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 con-

trol the quality of accessories or

parts manufactured by other com-

panies, Yamaha cannot be held lia-

Tightening torques:

Valve stem nut:

1.6 Nm (0.16 m·kgf, 1.2 ft·lb)

Valve stem locknut:

1.6 Nm (0.16 m·kgf, 1.2 ft·lb)

u5gk12.book Page 25 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-26

ble for any consequences caused

by the use of items which have not

been approved by Yamaha.

EAU00695

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 lev-

el and check the hydraulic system for

leakage before each ride. If the clutch

lever free play does become exces-

sive, and shifting becomes rough or

clutch slippage occurs, causing poor

acceleration, there may be air in the

clutch system. If there is air in the hy-

draulic system, have a Yamaha dealer

bleed the system before operating the

motorcycle.

u5gk12.book Page 26 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-27

EAU00696

Adjusting the brake lever free

play

The brake lever free play should mea-

sure 2–5 mm (0.08–0.20 in) as shown.

Periodically check the brake lever free

play and, if necessary, adjust it as fol-

lows.

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.

EW000099

WARNING

●After adjusting the brake lever

free play, check the free play

and make sure that the brake is

working properly.

●A soft or spongy feeling in the

brake lever can indicate the

presence of air in the hydraulic

system. If there is air in the hy-

draulic system, have a Yamaha

dealer bleed the system before

operating the motorcycle. Air in

the hydraulic system will dimin-

ish the braking performance,

which may result in loss of con-

trol and an accident.

EAU00712

Adjusting the brake pedal

position

The top of the brake pedal should be po-

sitioned approximately 20 mm (0.8 in)

below the top of the footrest as shown.

Periodically check the brake pedal posi-

tion and, if necessary, have a Yamaha

dealer adjust it.

1. Locknut

2. Brake lever free play adjusting bolt

c. Brake lever free play

a. Distance between brake pedal and footrest

u5gk12.book Page 27 Wednesday, June 13, 2001 8:55 AM

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6-28

EW000109

WARNING

A soft or spongy feeling in the brake

pedal can indicate the presence of

air in the hydraulic system. If there

is air in the hydraulic system, have a

Yamaha dealer bleed the system be-

fore operating the motorcycle. Air in

the hydraulic system will diminish

the braking performance, which

may result in loss of control and an

accident.

EAU00713

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

rear brake light switch in place. To

make the brake light come on earlier,

turn the adjusting nut in direction a. To

make the brake light come on later,

turn the adjusting nut in direction b.

EAU00715

Checking the front and rear

brake pads

The front and rear brake pads must be

checked for wear at the intervals spec-

ified in the periodic maintenance and

lubrication chart. Each brake pad is

provided with a wear indicator, which

allows you to check the brake pad wear

without having to disassemble the

brake. To check the brake pad wear,

check the position of the wear indicator

while applying the brake. If a brake pad

has worn to the point that the wear indi-

cator almost touches the brake disc,

have a Yamaha dealer replace the

brake pads as a set.

1. Rear brake light switch

2. Rear brake light switch adjusting nut

1. Brake pad wear indicator (× 2)

u5gk12.book Page 28 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-29

EAU04169

Checking the brake and clutch

fluid levels

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 flu-

id level may indicate worn brake pads

and/or brake system leakage. If the

brake level is low, be sure to check the

brake pads for wear and the brake sys-

tem for leakage.

NOTE:

The rear brake fluid reservoir is located

behind panel B. (See page 6-9 for panel

removal and installation procedures.)

Observe these precautions:

●When checking the fluid level,

make sure that the top of the brake

or clutch fluid reservoir is level.

●Use only the recommended quali-

ty brake fluid, otherwise the rubber

seals may deteriorate, causing

leakage and poor braking or clutch

performance.

●Refill with the same type of brake

fluid. Mixing fluids may result in a

harmful chemical reaction and

lead to poor braking or clutch per-

formance.

●The brake or clutch fluid reservoir

diaphragm will lose its shape from

the negative pressure if the fluid

level goes down too far. Be sure to

return the diaphragm to its original

shape before installing it into the

brake or clutch fluid reservoir.

●Be careful that water does not enter

the brake or clutch fluid reservoir

when refilling. Water will significantly

lower the boiling point of the fluid

and may result in vapor lock.

1. Minimum level mark

Front brake

1. Minimum level mark

Recommended brake and clutch

fluid: DOT 4 brake fluid

Clutch

1. Panel B

2. Minimum level mark

Rear brake

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-30

●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

gradually go down. However, if the

brake fluid level goes down sud-

denly, have a Yamaha dealer

check the cause.

EAU03984

Changing the brake and

clutch fluids

Have a Yamaha dealer change the

brake and clutch fluids at the intervals

specified in the NOTE after the periodic

maintenance and lubrication chart. In

addition, have the oil seals of the brake

and clutch master 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.

EAU03297

Checking and lubricating the

cables

The operation of all control cables and

the condition of the cables should be

checked before each ride, and the ca-

bles and cable ends should be lubricat-

ed if necessary. If a cable is damaged

or does not move smoothly, have a

Yamaha dealer check or replace it.

EW000111

WARNING

Damage to the outer housing of ca-

bles may result in internal rusting

and cause interference with cable

movement. Replace damaged ca-

bles as soon as possible to prevent

unsafe conditions.

Recommended lubricant:

Yamaha Chain and Cable Lube

or engine oil SAE 10W-30

(API SE)

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-31

EAU03364

Checking and lubricating the

throttle grip and cable

The operation of the throttle grip and

the condition of the throttle cable

should be checked before each ride,

and the cable should be lubricated or

replaced if necessary.

NOTE:

Since the throttle grip must be removed

to access the throttle cable end, the

throttle grip and the cable should al-

ways be lubricated at the same time.

1. Remove the throttle grip by remov-

ing the screws.

2. Disconnect the throttle cable, hold

it up, and then apply several drops

of oil to the cable end, allowing it to

trickle into the sheath.

3. Connect the throttle cable, and

then grease the inside of the throt-

tle grip housing.

4. Grease the metal-to-metal contact

surface of the throttle grip, and

then install the grip by installing

the screws.

EAU03370

Checking and lubricating the

brake and shift pedals

The operation of the brake and shift

pedals should be checked before each

ride, and the pedal pivots should be lu-

bricated if necessary.

Recommended lubricant:

Throttle cable:

Yamaha Chain and Cable

Lube or engine oil

SAE 10W-30

Throttle grip housing and grip:

Lithium-soap-based grease

(all-purpose grease)

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

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6-32

EAU03164

Checking and lubricating the

brake and clutch levers

The operation of the brake and clutch

levers should be checked before each

ride, and the lever pivots should be lu-

bricated if necessary.

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

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6-33

EAU03371

Checking and lubricating the

centerstand and sidestand

The operation of the centerstand and

sidestand should be checked before

each ride, and the pivots and metal-to-

metal contact surfaces should be lubri-

cated if necessary.

EW000114

WARNING

If the centerstand or sidestand does

not move up and down smoothly,

have a Yamaha dealer check or re-

pair it.

EAU03166

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:

Lithium-soap-based grease

(all-purpose grease)

Recommended lubricant:

Lithium-soap-based grease

(all-purpose grease)

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6-34

EAU02939

Checking the front fork

The condition and operation of the front

fork must be checked as follows at the

intervals specified in the periodic main-

tenance and lubrication chart.

To check the condition

EW000115

WARNING

Securely support the motorcycle so

that there is no danger of it falling

over.

Check the inner tubes for scratches,

damage and excessive oil leakage.

To check the operation

1. Place the motorcycle on a level

surface and hold it in an upright

position.

2. While applying the front brake,

push down hard on the handle-

bars several times to check if the

front fork compresses and re-

bounds smoothly.

EC000098

CAUTION:

If any damage is found or the front

fork does not operate smoothly,

have a Yamaha dealer check or re-

pair it.

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PERIODIC MAINTENANCE AND MINOR REPAIR

6-35

EAU00794

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 lubrication

chart.

1. Place a stand under the engine to

raise the front wheel off the

ground.

EW000115

WARNING

Securely support the motorcycle so

that there is no danger of it falling

over.

2. Hold the lower ends of the front

fork legs and try to move them for-

ward and backward. If any free

play can be felt, have a Yamaha

dealer check or repair the steer-

ing.

EAU01144

Checking the wheel bearings

The front and rear wheel bearings must

be checked at the intervals specified in

the periodic maintenance and lubrica-

tion chart. If there is play in the wheel

hub or if the wheel does not turn

smoothly, have a Yamaha dealer

check the wheel bearings.

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6-36

EAU04165

Battery

A poorly maintained battery will cor-

rode and discharge quickly. The elec-

trolyte level, battery lead connections

and breather hose routing should be

checked before each ride and at the in-

tervals specified in the periodic mainte-

nance and lubrication chart.

To check the electrolyte level

1. Place the motorcycle on a level

surface and hold it in an upright

position.

NOTE:

Make sure that the motorcycle is posi-

tioned straight up when checking the

electrolyte level.

2. Check the electrolyte level in the

battery.

NOTE:

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 for rider seat removal

and installation procedures.)

1. Battery

2. Battery breather hose

3. Pass through the cable guide.

1. Maximum level mark

2. Minimum level mark

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6-37

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 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.

EW000116

WARNING

●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 batteries. In case

of contact, administer the fol-

lowing FIRST AID.

•EXTERNAL: Flush with plenty

of water.

•INTERNAL: Drink large quan-

tities of water or milk and im-

mediately call a physician.

•EYES: Flush with water for

15 minutes and seek prompt

medical attention.

●Batteries produce explosive hy-

drogen gas. Therefore, keep

sparks, flames, cigarettes, etc.,

away from the battery and pro-

vide sufficient ventilation when

charging it in an enclosed

space.

1. Starter moter lead (black)

2. Positive battery lead (red)

3. Negative battery lead

1. Ignition coil assembly (× 2)

2. Bolt (× 2)

3. Coupler (× 4)

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6-38

●KEEP THIS AND ALL BATTER-

IES OUT OF THE REACH OF

CHILDREN.

EC000100

CAUTION:

Use only distilled water, as tap water

contains minerals that are harmful

to the battery.

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 the positive

battery lead and the starter motor

lead to the starter motor relay.

EW000118

WARNING

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 seat.

1. Battery

2. Battery breather hose

3. Pass through the cable guide.

1. Positive battery lead (red)

2. Starter motor lead (black)

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6-39

To store the battery

1. If the motorcycle will not be used

for more than one month, remove

the battery, fully charge it, and

then place it in a cool, dry place.

2. If the battery will be stored for

more than two months, check the

specific gravity of the electrolyte at

least once a month and fully

charge the battery whenever nec-

essary.

3. Fully charge the battery before in-

stallation.

4. After installation, make sure that

the battery leads are properly con-

nected to the battery terminals and

that the breather hose is properly

routed, in good condition, and not

obstructed.

EC000099

CAUTION:

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.

EAU01664

Replacing the fuses

The main fuse box is located under the

rider seat. (See page 3-9 for rider seat

removal and installation procedures.)

The fuse box, which contains the fuses

for the individual circuits, is located un-

der cowling A. (See page 6-8 for cowl-

ing removal and installation proce-

dures.)

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 the specified

amperage.

1. Main fuse

2. Spare main fuse

u5gk12.book Page 39 Wednesday, June 13, 2001 8:55 AM

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6-40

EC000103

CAUTION:

Do not use a fuse of a higher amper-

age rating than recommended to

avoid causing extensive damage to

the electrical system and possibly a

fire.

3. Turn the key to “ON” and turn on

the electrical circuit in question to

check if the device operates.

4. If the fuse immediately blows

again, have a Yamaha dealer

check the electrical system.

1. Headlight fuse

2. Signaling system fuse

3. Ignition fuse

4. Radiator fan fuse

5. Spare fuse (× 2)

Specified fuses:

Main fuse: 30 A

Headlight fuse: 15 A

Signaling system fuse: 10 A

Radiator fan fuse: 10 A

Ignition fuse: 10 A

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6-41

EAU04187

Replacing the headlight bulb

This motorcycle 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.

EW000119

WARNING

Headlight bulbs get very hot. There-

fore, keep flammable products away

from a lit headlight bulb, and do not

touch the bulb until it has cooled

down.

4. Place a new headlight bulb into

position, and then secure it with

the bulb holder.

EC000105

CAUTION:

Do not touch the glass part of the

headlight bulb to keep it free from

oil, otherwise the transparency of

the glass, the luminosity of the bulb,

and the bulb life will be adversely af-

fected. Thoroughly clean off any dirt

and fingerprints on the headlight

bulb using a cloth moistened with

alcohol 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.

1. Screw (× 2) 1. Headlight bulb holder 1. Do not touch this area.

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EAU00855

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 in and turning it counter-

clockwise.

3. Insert a new bulb into the socket,

push it in, and then turn it clock-

wise until it stops.

4. Install the lens by installing the

screws.

EC000108

CAUTION:

Do not overtighten the screws, oth-

erwise the lens may break.

1. Screw (× 2) 1. Tail/brake light bulb (× 2) 1. Turn signal light bulb

u5gk12.book Page 42 Wednesday, June 13, 2001 8:55 AM

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6-43

EAU04163

Front wheel

To remove the front wheel

EW000122

WARNING

●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. 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.

ECA00047

CAUTION:

Do not pull the brake lever after the

brake caliper has been removed,

otherwise the brake pads will be

forced shut.

4. Loosen the front wheel axle pinch

bolt, then the wheel axle.

5. Pull the wheel axle out, and then

remove the wheel.

EAU04164

To install the front wheel

1. Install the speedometer gear unit

into the wheel hub so that the pro-

jections mesh with the slots.

1. Speedometer cable

2. Bolt (× 2)

3. Front wheel axle pinch bolt

4. Wheel axle

u5gk12.book Page 43 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-44

2. Lift the wheel up between the fork

legs.

NOTE:

Make sure that the slot in the speedom-

eter gear unit fits over the retainer on

the fork leg.

3. Insert the wheel axle.

4. Take the motorcycle off the cen-

terstand so that the front wheel is

on the ground.

5. Install the brake calipers by install-

ing the bolts.

NOTE:

Make sure that there is enough space

between the brake pads before install-

ing the brake calipers onto the brake

discs.

6. Tighten the wheel axle, then 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.

Tightening torques:

Wheel axle:

58 Nm (5.8 m·kgf, 42 ft·lb)

Front wheel axle pinch bolt:

20 Nm (2.0 m·kgf, 14 ft·lb)

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lb)

u5gk12.book Page 44 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-45

EAU03421

Rear wheel

To remove the rear wheel

EW000122

WARNING

●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. Loosen the rear wheel axle pinch

bolt, and the axle nut.

2. Place the motorcycle on the cen-

terstand.

3. Remove the brake caliper bolts

and the axle nut.

4. Disconnect the brake torque rod

from the brake caliper bracket by

removing the cotter pin, the nut,

and the bolt.

1. Axle nut 1. Rear wheel axle pinch bolt 1. Nut

2. Cotter pin

3. Brake torque rod

4. Bolt (× 3)

5. Spacer

6. Brake caliper bracket

u5gk12.book Page 45 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-46

5. While supporting the brake cali-

per, pull the wheel axle out.

6. Remove the brake caliper bracket

and spacer.

7. Pull the wheel to the right to sepa-

rate it from the final gear case, and

then remove it.

ECA00062

CAUTION:

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.

EAU03422

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

bracket, spacer and wheel axle.

3. Install the brake caliper by install-

ing the bolts.

NOTE:

Make sure that there is enough space

between the brake pads before install-

ing the brake caliper onto the brake

disc.

4. Install the brake torque rod bolt and

nut at the brake caliper bracket.

5. Install the rear wheel axle nut.

6. Take the motorcycle off the cen-

terstand so that the rear wheel is

on the ground.

7. Tighten the axle nut, brake caliper

bolts, brake torque rod nut, and

pinch bolt to the specified torques.

8. Install the brake torque rod cotter

pin.

EW000124

WARNING

Always use a new cotter pin.

Tightening torques:

Axle nut:

150 Nm (15.0 m·kgf, 108 ft·lb)

Brake caliper bolt:

40 Nm (4.0 m·kgf, 29 ft·lb)

Brake torque rod nut:

23 Nm (2.3 m·kgf, 17 ft·lb)

Rear wheel axle pinch bolt:

16 Nm (1.6 m·kgf, 11 ft·lb)

u5gk12.book Page 46 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-47

EAU03087

Troubleshooting

Although Yamaha motorcycles receive

a thorough inspection before shipment

from the factory, trouble may occur dur-

ing operation. Any problem in the fuel,

compression, 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 skilled technicians have

the necessary tools, experience, and

know-how to service the motorcycle

properly.

Use only genuine Yamaha replace-

ment parts. Imitation parts may look

like Yamaha parts, but they are often

inferior, have a shorter service life and

can lead to expensive repair bills.

u5gk12.book Page 47 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-48

EAU03363

Troubleshooting charts

Starting problems or poor engine performance

EW000125

WARNING

Keep away open flames and do not smoke while checking or working on the fuel system.

Check the fuel level in

the fuel tank.

1. Fuel

There is enough fuel.

There is no fuel.

Check the compression.

Supply fuel.

Operate the electric starter.

2. Compression

There is compression.

There is no compression.

Check the ignition.

Have a Yamaha dealer

check 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

slowly.

The battery is good.

Check the electrolyte and battery

lead connections, and charge the

battery if necessary.

The engine does not start.

Have a Yamaha dealer

check the vehicle.

The engine does not start.

Check the compressoin.

u5gk12.book Page 48 Wednesday, June 13, 2001 8:55 AM

PERIODIC MAINTENANCE AND MINOR REPAIR

6-49

Engine overheating

EW000070

WARNING

●Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be

blown out under pressure, which could cause serious injury. Be sure to wait until the engine has cooled.

●After removing the radiator cap retaining bolt, place a thick rag, like a towel, over the radiator cap, and then

slowly rotate the cap counterclockwise to the detent to allow any residual pressure to escape. When the hiss-

ing sound has stopped, press down on the cap while turning it counterclockwise, and then remove the cap.

NOTE:

If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant

as soon as possible.

Wait until the

engine has cooled.

Check the coolant level in the

reservoir and radiator.

The coolant level

is OK.

The coolant level is low.

Check the cooling system

for leakage.

Have a Yamaha dealer check

and repair the cooling system.

Add coolant. (See NOTE.)

Start the engine. If the engine overheats again, have a

Yamaha dealer check

and repair the cooling system.

There is

leakage.

There is

no leakage.

u5gk12.book Page 49 Wednesday, June 13, 2001 8:55 AM

MOTORCYCLE CARE AND STORAGE

Care .................................................................................................. 7-1

Storage .............................................................................................. 7-4

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

7-1

EAU03412

MOTORCYCLE CARE AND STORAGE

Care

While the open design of a motorcycle

reveals the attractiveness of the tech-

nology, it also makes it more vulnera-

ble. Rust and corrosion can develop

even if high-quality components are

used. A rusty exhaust pipe may go un-

noticed on a car, however, it detracts

from the overall appearance of a

motorcycle. Frequent and proper care

does not only comply with the terms of

the warranty, but it will also keep your

motorcycle looking good, extend its life

and optimize its performance.

Before cleaning

1. Cover the muffler outlets with plas-

tic bags after the engine has

cooled down.

2. Make sure that all caps and covers

as well as all electrical couplers

and connectors, including the

spark plug caps, are tightly in-

stalled.

3. Remove extremely stubborn dirt,

like oil burnt onto the crankcase,

with a degreasing agent and a

brush, but never apply such prod-

ucts onto seals, gaskets and

wheel axles. Always rinse the dirt

and degreaser off with water.

Cleaning

ECA00010

CAUTION:

●Avoid using strong acidic wheel

cleaners, especially on spoked

wheels. If such products are

used on hard-to-remove dirt, do

not 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

corrosion 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.

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

MOTORCYCLE CARE AND STORAGE

7-2

●Do not use any harsh chemical

products on plastic parts. Be

sure to avoid using cloths or

sponges which have been in

contact with strong or abrasive

cleaning products, solvent or

thinner, fuel (gasoline), rust re-

movers or inhibitors, brake flu-

id, antifreeze or electrolyte.

●Do not use high-pressure wash-

ers or steam-jet cleaners since

they cause water seepage and

deterioration in the following ar-

eas: seals (of wheel and swing-

arm bearings, fork and brakes),

electric components (couplers,

connectors, instruments, switch-

es and lights), breather hoses

and vents.

●For motorcycles equipped with

a windshield: Do not use strong

cleaners or hard sponges as

they will cause dulling or

scratching. Some cleaning

compounds for plastic may

leave scratches on the wind-

shield. Test the product on a

small hidden part of the wind-

shield to make sure that it does

not leave any marks. If the wind-

shield is scratched, use a quali-

ty plastic polishing compound

after washing.

After normal use

Remove dirt with warm water, a mild

detergent, and a soft, clean sponge,

and then rinse thoroughly with clean

water. Use a toothbrush or bottlebrush

for hard-to-reach areas. Stubborn dirt

and insects will come off more easily if

the area is covered with a wet cloth for

a few minutes before cleaning.

After riding in the rain, near the sea or

on salt-sprayed roads

Since sea salt or salt sprayed on roads

during winter are extremely corrosive in

combination with water, carry out the

following steps after each ride in the

rain, near the sea or on salt-sprayed

roads.

NOTE:

Salt sprayed on roads in the winter may

remain well into spring.

1. Clean the motorcycle with cold

water and a mild detergent, after

the engine has cooled down.

ECA00012

CAUTION:

Do not use warm water since it in-

creases the corrosive action of the

salt.

2. After drying the motorcycle, apply

a corrosion protection spray on all

metal, including chrome- and nick-

el-plated, surfaces to prevent cor-

rosion.

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

MOTORCYCLE CARE AND STORAGE

7-3

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 nickel-plat-

ed, surfaces.

4. Use spray oil as a universal clean-

er to remove any remaining dirt.

5. Touch up minor paint damage

caused by stones, etc.

6. Wax all painted surfaces.

7. Let the motorcycle dry completely

before storing or covering it.

EWA00031

WARNING

●Make sure that there is no oil or

wax on the brakes or tires.

●If necessary, clean the brake

discs and brake linings with a

regular brake disc cleaner or ac-

etone, and wash the tires with

warm water and a mild deter-

gent. Before riding at higher

speeds, test the motorcycle’s

braking performance and cor-

nering behavior.

ECA00013

CAUTION:

●Apply spray oil and wax spar-

ingly and make sure to wipe off

any excess.

●Never apply oil or wax to any

rubber and plastic parts, but

treat them with a suitable care

product.

●Avoid using abrasive polishing

compounds as they will wear

away the paint.

NOTE:

Consult a Yamaha dealer for advice on

what products to use.

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

MOTORCYCLE CARE AND STORAGE

7-4

Storage

Short-term

Always store your motorcycle in a cool,

dry place and, if necessary, protect it

against dust with a porous cover.

ECA00014

CAUTION:

●Storing the motorcycle in a

poorly ventilated room or cover-

ing it with a tarp, while it is still

wet, will allow water and humid-

ity to seep in and cause rust.

●To prevent corrosion, avoid

damp cellars, stables (because

of the presence of ammonia)

and areas where strong chemi-

cals are stored.

Long-term

Before storing your motorcycle for

several months:

1. Follow all the instructions in the

“Care” section of this chapter.

2. For motorcycles equipped with a

fuel cock 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 cylinders, piston rings, etc.

from corrosion.

a. Remove the spark plug caps and

spark plugs.

b. Pour a teaspoonful of engine oil

into each spark plug bore.

c. Install the spark plug caps onto the

spark plugs, and then place the

spark plugs on the cylinder head

so that the electrodes are ground-

ed. (This will limit sparking during

the next step.)

d. Turn the engine over several times

with the starter. (This will coat the

cylinder walls with oil.)

e. Remove the spark plug caps from

the spark plugs, and then install

the spark plugs and the spark plug

caps.

EWA00003

WARNING

To prevent damage or injury from

sparking, make sure to ground the

spark plug electrodes while turning

the engine over.

u5gk12.book Page 4 Wednesday, June 13, 2001 8:55 AM

MOTORCYCLE CARE AND STORAGE

7-5

6. Lubricate all control cables and

the pivoting points of all levers and

pedals as well as of the sidestand/

centerstand.

7. Check and, if necessary, correct

the tire air pressure, and then lift

the motorcycle so that both of its

wheels are off the ground. Alterna-

tively, turn the wheels a little every

month in order to prevent the tires

from becoming degraded in one

spot.

8. Cover the muffler outlets with plas-

tic bags to prevent moisture from

entering them.

9. Remove the battery and fully

charge it. Store it in a cool, dry

place and charge it once a month.

Do not store the battery in an ex-

cessively cold or warm place [less

than 0 °C (30 °F) or more than

30 °C (90 °F)]. For more informa-

tion on storing the battery, see

page 6-39.

NOTE:

Make any necessary repairs before

storing the motorcycle.

u5gk12.book Page 5 Wednesday, June 13, 2001 8:55 AM

SPECIFICATIONS

Specifications .................................................................................... 8-1

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

8-1

EAU01038

SPECIFICATIONS

Specifications

CS-01E

Model VMX12/VMX12C

Dimensions

Overall length 2,300 mm (90.6 in)

Overall width 795 mm (31.3 in)

Overall height 1,160 mm (45.7 in)

Seat height 765 mm (30.1 in)

Wheelbase 1,590 mm (62.6 in)

Ground clearance 145 mm (5.7 in)

Minimum turning radius 2,900 mm (114.2 in)

Basic weight (with oil and full

fuel tank)

VMX12 283 kg (624 lb)

VMX12C 284 kg (626 lb)

Engine

Engine type Liquid-cooled 4-stroke, DOHC

Cylinder arrangement V type, 4-cylinder

Displacement 1,198 cm3

Bore × stroke 76 × 66 mm (3.0 × 2.6 in)

Compression ratio 10.5:1

Starting system Electric starter

Lubrication system Wet sump

Engine oil

Ty p e

Recommended engine oil

classification API Service SE, SF, SG or

higher

Quantity

Without oil filter cartridge

replacement 3.2 L (2.8 Imp qt, 3.4 US qt)

With oil filter cartridge

replacement 3.4 L (3.0 Imp qt, 3.6 US qt)

Total amount (dry engine) 4.0 L (3.5 Imp qt, 4.2 US qt)

010 30 50 70 90 110 130 ˚F

YAMALUBE 4 (20W-40)

or SAE 20W-40

-20 -10 010 20 30 40 50 ˚C

YAMALUBE 4 (10W-30)

or SAE 10W-30

CAUTION:

Be sure to use motor oils that do not contain anti-friction

modifiers. Passenger car motor oils (often labeled

“ENERGY CONSERVING II”) contain anti-friction additives

which will cause clutch and/or starter clutch slippage, result-

ing in reduced component life and poor engine performance.

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

SPECIFICATIONS

8-2

Final gear oil

Type Hypoid gear oil SAE80 (API

GL4) or multi-grade hypoid gear

oil SAE80W-90

Quantity 0.2 L (0.18 Imp qt, 0.21 US qt)

Cooling system capacity

(total amount) 3.05 L (2.68 Imp qt, 3.22 US qt)

Air filter Dry type element

Fuel

Type UNLEADED GASOLINE ONLY

Fuel tank capacity 15 L (3.3 Imp gal, 4.0 US gal)

Fuel reserve amount 3 L (0.7 Imp gal, 0.8 US gal)

Carburetor

Manufacturer MIKUNI

Model × quantity BDS35 × 4

Spark plug

Manufacturer/model DPR8EA-9 / NGK or

X24EPR-U9 / DENSO

Gap 0.8–0.9 mm (0.03–0.04 in)

Clutch type Wet, multiple-disc

Transmission

Primary reduction system Spur gear

Primary reduction ratio 1.775

Secondary reduction system Shaft drive

Secondary reduction ratio 2.851

Transmission type Constant mesh, 5-speed

Operation Left foot

Gear ratio

1st 2.529

2nd 1.772

3rd 1.347

4th 1.076

5th 0.928

Chassis

Frame type Double cradle

Caster angle 29°

Trail 119 mm (4.69 in)

Tires

Front

Type Tubeless tire

110/90-18 M/C 61V

Size 110/90-18 61V

Manufacturer/

model Bridgestone / G525AW

Dunlop / F20

Rear

Type Tubeless tire

Size 150/90-15 M/C 74V

Manufacturer/

model Bridgestone / G526BW

Dunlop / K525

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

SPECIFICATIONS

8-3

Maximum load*

VMX12 216 kg (476 lb)

VMX12C 215 kg (474 lb)

Tire air pressure (measured

on cold tires)

Up to 90 kg (198 lb)*

Front 225 kPa (2.25 kgf/cm2, 33 psi)

Rear 225 kPa (2.25 kgf/cm2, 33 psi)

90 kg (198 lb)–maximum*

Front 225 kPa (2.25 kgf/cm2, 33 psi)

Rear 250 kPa (2.50 kgf/cm2, 36 psi)

High-speed riding

Front 225 kPa (2.25 kgf/cm2, 33 psi)

Rear 250 kPa (2.50 kgf/cm2, 36 psi)

* Total weight of rider, passenger, cargo and accessories

Wheels

Front

Type Cast wheel

Size 18 × MT 2.15

Rear

Type Cast wheel

Size 15M/C × MT 3.50

Brakes

Front

Type Dual disc brake

Operation Right hand

Fluid DOT 4

Rear

Type Single disc brake

Operation Right foot

Fluid DOT 4

Suspension

Front Telescopic fork

Rear Swingarm

Spring/shock absorber

Front Coil-air spring / oil damper

Rear Coil spring / oil damper

Wheel travel

Front 140 mm (5.5 in)

Rear 100 mm (3.9 in)

Electrical system

Ignition system T.C.I. (digital)

Charging system

Type A.C. magneto

Standard output 14 V, 22.5 A@ 5,000 r/min

Battery

Model YB16AL-A2

Voltage, capacity 12 V, 16 Ah

Headlight type Quartz bulb (halogen)

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

SPECIFICATIONS

8-4

Bulb voltage, wattage × quantity

Headlight 12 V, 60/55 W × 1

Tail/brake light 12 V, 8/27 W × 2

Front turn signal/position light 12 V, 27/8 W × 2

Rear turn signal light 12 V, 27 W × 2

Meter lighting 14 V, 3 W × 2

Neutral indicator light 14 V, 3 W × 1

High beam indicator light 14 V, 3 W × 1

Turn signal indicator light 14 V, 3 W × 1

Fuel level warning light 14 V, 3 W × 1

Oil level warning light 14 V, 3 W × 1

Fuses

Main fuse 30 A

Headlight fuse 15 A

Signaling system fuse 10 A

Radiator fan fuse 10 A

Ignition fuse 10 A

u5gk12.book Page 4 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

Identification numbers ....................................................................... 9-1

Key identification number .................................................................. 9-1

Vehicle identification number ............................................................. 9-1

Model label ........................................................................................ 9-2

Reporting safety defects ................................................................... 9-3

Motorcycle noise regulation .............................................................. 9-4

Maintenance record .......................................................................... 9-5

YAMAHA MOTOR CORPORATION, U.S.A. STREET AND

ENDURO MOTORCYCLE LIMITED WARRANTY .......................... 9-7

YAMAHA EXTENDED SERVICE (Y.E.S.) ......................................... 9-9

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

9-1

EAU01039

CONSUMER INFORMATION

EAU02944

Identification numbers

Record the key identification number,

vehicle identification number and mod-

el label information in the spaces pro-

vided below for assistance when

ordering spare parts from a Yamaha

dealer or for reference in case the vehi-

cle is stolen.

1. KEY IDENTIFICATION NUMBER:

CA-02E

2. VEHICLE IDENTIFICATION

NUMBER:

CA-02E

3. MODEL LABEL INFORMATION:

CA-01E

EAU01042

Key identification number

The key identification number is

stamped into the key. Record this num-

ber in the space provided and use it for

reference when ordering a new key.

EAU01043

Vehicle identification number

The vehicle identification number is

stamped into the steering head pipe.

Record this number in the space pro-

vided.

NOTE:

The vehicle identification number is

used to identify your motorcycle and

may be used to register your motor-

cycle with the licensing authority in

your area.

1. Key identification number 1. Vehicle identification number

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-2

EAU03424

Model label

The model label is affixed under cowl-

ing A. (See page 6-8 for cowling re-

moval and installation procedures.)

Record the information on this label in

the space provided. This information

will be needed when ordering spare

parts from a Yamaha dealer.

1. Model label

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-3

EAU01051

Reporting safety defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immedi-

ately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation,

U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in group

of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems

between you, your dealer, or Yamaha Motor Corporation, U.S.A.

To contact NHTSA, you may either call the Auto Safety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.

area) or write to: NHTSA, U.S. Department of Transportation, Washington, D.C. 20590. You can also obtain other informa-

tion about motor vehicle safety from the Hotline.

u5gk12.book Page 3 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-4

EAU01053

Motorcycle noise regulation

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other

than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve-

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.

CL-01E

Exhaust system

Muffler

Exhaust pipe

Silencer

Intake system

Air cleaner case

Air cleaner element

Intake duct

u5gk12.book Page 4 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-5

EAU01874

Maintenance record

Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that

maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder

that maintenance work is required. It is not acceptable proof of maintenance work.

CL-04E

Maintenance

interval

Date of

service Mileage Servicing dealer

name and address Remarks

600 mi

(1,000 km) or

1 month

4,000 mi

( 7,000 km) or

6 months

8,000 mi

(13,000 km) or

12 months

12,000 mi

(19,000 km) or

18 months

16,000 mi

(25,000 km) or

24 months

20,000 mi

(31,000 km) or

30 months

24,000 mi

(37,000 km) or

36 months

u5gk12.book Page 5 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-6

28,000 mi

(43,000 km) or

42 months

32,000 mi

(49,000 km) or

48 months

36,000 mi

(55,000 km) or

54 months

40,000 mi

(61,000 km) or

60 months

Maintenance

interval

Date of

service Mileage Servicing dealer

name and address Remarks

u5gk12.book Page 6 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-7

EAU02918

YAMAHA MOTOR CORPORATION, U.S.A.

STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY

u5gk12.book Page 7 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-8

u5gk12.book Page 8 Wednesday, June 13, 2001 8:55 AM

CONSUMER INFORMATION

9-9

EAU01063

YAMAHA EXTENDED SERVICE (Y.E.S.)

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CONSUMER INFORMATION

9-10

u5gk12.book Page 10 Wednesday, June 13, 2001 8:55 AM

10-

INDEX

Accessories and replacement parts .......6-25

Air filter element, cleaning......................6-21

Battery ...................................................6-36

Brake and clutch fluid levels, checking...6-29

Brake and clutch fluids, changing...........6-30

Brake and clutch levers, checking and

lubricating ............................................6-32

Brake and shift pedals, checking and

lubricating ............................................6-31

Brake lever...............................................3-5

Brake lever free play, adjusting ..............6-27

Brake light switch (rear), adjusting .........6-28

Brake pads, checking.............................6-28

Brake pedal..............................................3-6

Brake pedal position, adjusting ..............6-27

Cables, checking and lubricating............6-30

Canister (for California only)...................6-11

Carburetors, adjusting............................6-22

Care.........................................................7-1

Centerstand and sidestand, checking

and lubricating .....................................6-33

Clutch lever..............................................3-5

Clutch lever free play .............................6-26

Coolant ..................................................6-16

Changing..........................................6-17

Checking ..........................................6-16

Coolant temperature gauge .....................3-3

Cowling and panels,

removing and installing ..........................6-8

Dimmer switch......................................... 3-3

Engine break-in ....................................... 5-5

Engine oil and oil filter cartridge............. 6-11

Engine stop switch................................... 3-4

Final gear oil.......................................... 6-15

Front fork, adjusting ............................... 3-11

Front fork, checking ............................... 6-34

Fuel ......................................................... 3-7

Fuel level warning light ............................ 3-2

Fuel reserve switch.................................. 3-4

Fuel tank cap........................................... 3-6

Fuses, replacing .................................... 6-39

Handlebar switches ................................. 3-3

Headlight bulb, replacing ....................... 6-41

Helmet holder........................................ 3-10

High beam indicator light ......................... 3-2

Horn switch ............................................. 3-4

Identification numbers ............................. 9-1

Ignition circuit cut-off system.................. 3-17

Indicator and warning lights ..................... 3-1

Key identification number ........................ 9-1

Labels, location ....................................... 1-7

Main switch ..............................................3-1

Maintenance and lubrication, periodic ......6-5

Maintenance, emission control system.....6-3

Maintenance, periodic ..............................6-1

Maintenance record .................................9-5

Model label ..............................................9-2

Neutral indicator light ...............................3-1

Noise regulation .......................................9-4

Oil level warning light ...............................3-2

Parking.....................................................5-6

Part locations ...........................................2-1

Pre-operation check list............................4-1

Rider seat ................................................3-9

Safety defects, reporting ..........................9-3

Safety information ....................................1-1

Shifting.....................................................5-3

Decelerating .......................................5-4

Shift points..........................................5-5

Starting out and accelerating ..............5-4

Shift pedal................................................3-5

Shock absorber assemblies, adjusting ...3-12

Sidestand...............................................3-17

Spark plugs, checking ..............................6-9

Specifications...........................................8-1

u5gk12.book Page 1 Wednesday, June 13, 2001 8:55 AM

INDEX

Speedometer unit .................................... 3-2

Starter (choke) lever ................................ 3-8

Starting and warming up a cold engine.... 5-1

Starting a warm engine............................ 5-3

Start switch.............................................. 3-4

Steering, checking ................................. 6-35

Steering lock............................................ 3-9

Storage.................................................... 7-4

Suspension (rear), lubricating ................ 6-33

Suspension settings, matching

front and rear....................................... 3-15

Tachometer ............................................. 3-3

Throttle cable free play, adjusting .......... 6-22

Throttle grip and cable, checking and

lubricating............................................ 6-31

Tires ...................................................... 6-23

Tool kit..................................................... 6-1

Troubleshooting..................................... 6-47

Troubleshooting charts .......................... 6-48

Turn signal indicator light......................... 3-1

Turn signal light bulb or

the tail/brake light bulb, replacing ........ 6-42

Turn signal switch.................................... 3-3

Valve clearance, adjusting..................... 6-22

V-Boost ................................................. 3-16

Vehicle identification number ................... 9-1

Warranty, extended................................. 9-9

Warranty, limited ..................................... 9-7

Wheel bearings, checking ..................... 6-35

Wheel (front) ......................................... 6-43

Installing .......................................... 6-43

Removing ........................................ 6-43

Wheel (rear).......................................... 6-45

Installing .......................................... 6-46

Removing ........................................ 6-45

Wheels.................................................. 6-25

u5gk12.book Page 2 Wednesday, June 13, 2001 8:55 AM

LIT-11626-15-11 5GK-28199-12

VMX12P

VMX12PC

OWNER’S MANUAL

PRINTED IN JAPAN

2001 · 4 - 0.9 × 1 CR

(E)

PRINTED ON RECYCLED PAPER

YAMAHA MOTOR CO., LTD.

Yamaha 2002 Vmax Owners Manual V Max

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