Vmax vmx12v

OWNER’S MANUAL
VMX12V(C)
5GK-28199-16
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EAU10041

INTRODUCTION
EAU10080
VMX12V. This model is the result of Yamaha’s vast experience in the pro-
acing machines. It represents the high degree of craftsmanship and reli-
ields.
e operation, inspection, and basic maintenance of this motorcycle. If you
maintenance of your motorcycle, please consult a Yamaha dealer.
orcycle fully comply with the emissions standards for clean air applicable
e standards without reducing the performance or economy of operation of
it is important that you and your Yamaha dealer pay close attention to the
ting instructions contained within this manual.

RMATION
EAU10130
in this manual by the following notations:

Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
WARNING instructions could result in severe injury or death to the

tor, a bystander or a person inspecting or repairing the motorcycle.
ates special precautions that must be taken to avoid damage to
key information to make procedures easier or clearer.
ent part of this motorcycle and should remain with it even if the motorcycle
product design and quality. Therefore, while this manual contains the most
me of printing, there may be minor discrepancies between your motorcycle
oncerning this manual, please consult your Yamaha dealer.
EWA10010
U AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY

S MOTORCYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCY-
E KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES
AFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS
H GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFELY ENJOY
F THIS MOTORCYCLE.

IMPORTANT MANUAL INFORMATION
EAU10192
AFFIX DEALER
LABEL HERE
VMX12V(C)
OWNER’S MANUAL
amaha Motor Corporation, U.S.A.
1st edition, April 2005
All rights reserved.
printing or unauthorized use
ut the written permission of
ha Motor Corporation, U.S.A.
s expressly prohibited.
Printed in Japan.
P/N LIT-11626-19-27

n circuit cut-off system ......... 3-15 Checking the throttle cable free
play ............................................ 6-19
ERATION CHECKS .............. 4-1 Valve clearance ............................ 6-20
peration check list ................... 4-2 Tires .............................................. 6-20
Cast wheels .................................. 6-22
TION AND IMPORTANT Accessories and replacement
POINTS .................................. 5-1 parts ........................................... 6-23
g and warming up a cold Clutch lever ................................... 6-23
ne .......................................... 5-1 Adjusting the brake lever free
g a warm engine ................... 5-2 play ............................................ 6-24
g ............................................ 5-3 Adjusting the rear brake light
e break-in ............................... 5-4 switch ......................................... 6-24
g ............................................ 5-5 Checking the front and rear brake
pads ........................................... 6-25
IC MAINTENANCE AND Checking the brake and clutch fluid
REPAIR .................................. 6-1 levels ......................................... 6-25
ODIC MAINTENANCE ............ 6-1 Changing the brake and clutch
’s tool kit ................................ 6-1 fluids .......................................... 6-26
ic maintenance chart for the Checking and lubricating the
ssion control system .............. 6-3 cables ........................................ 6-27
al maintenance and lubrication Checking and lubricating the throttle
t ............................................. 6-4 grip and cable ............................ 6-27
ving and installing the cowling Checking and lubricating the brake
panels ................................... 6-8 and shift pedals ......................... 6-27
ing the spark plugs ................ 6-9 Checking and lubricating the brake
er (for California only) ......... 6-10 and clutch levers ........................ 6-28
e oil and oil filter cartridge .... 6-11 Checking and lubricating the
gear oil .................................. 6-14 centerstand and sidestand ........ 6-28
nt .......................................... 6-15 Lubricating the rear suspension .... 6-29
ng the air filter element ....... 6-18 Checking the front fork .................. 6-29
retors ................................... 6-19 Checking the steering ................... 6-30

TABLE OF CONTENTS

ONS. motorist’s blind spot.
● Many accidents involve inexperi-
ding enced operators. In fact, many op-
ways make pre-operation erators who have been involved in
ecks. Careful checks may help accidents do not even have a cur-
vent an accident. rent motorcycle license.
s motorcycle is designed to car- ● Make sure that you are qualified
he operator and a passenger. and that you only lend your mo-
e failure of motorists to detect torcycle to other qualified opera-
d recognize motorcycles in traf- tors.
is the predominating cause of ● Know your skills and limits.
omobile/motorcycle accidents. Staying within your limits may
ny accidents have been caused help you to avoid an accident.
an automobile driver who did ● We recommend that you prac-
see the motorcycle. Making tice riding your motorcycle
urself conspicuous appears to where there is no traffic until you
very effective in reducing the have become thoroughly famil-
ance of this type of accident. iar with the motorcycle and all of
erefore: its controls.
Wear a brightly colored jacket. ● Many accidents have been caused
Use extra caution when you are by error of the motorcycle opera-
pproaching and passing tor. A typical error made by the op-
hrough intersections, since in- erator is veering wide on a turn
ersections are the most likely due to EXCESSIVE SPEED or un-
laces for motorcycle accidents dercornering (insufficient lean an-
o occur. gle for the speed).
Ride where other motorists can ● Always obey the speed limit and
ee you. Avoid riding in another never travel faster than warrant-
1-1

SAFETY INFORMATION
idents are the result of head in- Modifications
The use of a safety helmet is the Modifications made to this motorcycle
most critical factor in the preven- not approved by Yamaha, or the re-
reduction of head injuries. moval of original equipment, may ren-
ways wear an approved helmet. der the motorcycle unsafe for use and 1
ear a face shield or goggles. may cause severe personal injury.
nd in your unprotected eyes Modifications may also make your mo-
uld contribute to an impairment torcycle illegal to use.
vision that could delay seeing a
zard. Loading and accessories
e use of a jacket, heavy boots, Adding accessories or cargo to your
users, gloves, etc., is effective in motorcycle can adversely affect stabili-
eventing or reducing abrasions ty and handling if the weight distribution
lacerations. of the motorcycle is changed. To avoid
ver wear loose-fitting clothes, the possibility of an accident, use ex-
herwise they could catch on the treme caution when adding cargo or
ntrol levers, footrests, or wheels accessories to your motorcycle. Use
d cause injury or an accident. extra care when riding a motorcycle
ver touch the engine or exhaust that has added cargo or accessories.
stem during or after operation. Here are some general guidelines to
ey become very hot and can follow if loading cargo or adding acces-
use burns. Always wear protec- sories to your motorcycle:
e clothing that covers your legs,
kles, and feet. Loading
passenger should also observe The total weight of the operator, pas-
e above precautions. senger, accessories and cargo must
not exceed the maximum load limit.
1-2

ories namic changes. If accessories
e Yamaha accessories have are added to the handlebar or
pecifically designed for use on front fork area, they must be as
orcycle. Since Yamaha cannot lightweight as possible and
other accessories that may be should be kept to a minimum.
e, you must personally be re- ● Bulky or large accessories may
le for the proper selection, in- seriously affect the stability of
n and use of non-Yamaha the motorcycle due to aerody-
ories. Use extreme caution namic effects. Wind may at-
electing and installing any ac- tempt to lift the motorcycle, or
es. the motorcycle may become un-
e following guidelines in mind, stable in cross winds. These ac-
as those provided under “Load- cessories may also cause
en mounting accessories. instability when passing or being
ver install accessories or carry passed by large vehicles.
go that would impair the perfor- ● Certain accessories can dis-
nce of your motorcycle. Care- place the operator from his or
y inspect the accessory before her normal riding position. This
ng it to make sure that it does improper position limits the free-
in any way reduce ground dom of movement of the opera-
arance or cornering clearance, tor and may limit control ability,
t suspension travel, steering therefore, such accessories are
vel or control operation, or ob- not recommended.
re lights or reflectors. ● Use caution when adding electri-
Accessories fitted to the handle- cal accessories. If electrical acces-
ar or the front fork area can sories exceed the capacity of the
reate instability due to improper motorcycle’s electrical system, an
weight distribution or aerody- electric failure could result, which
1-3

SAFETY INFORMATION
motorcycle in a place where pe-
destrians or children are not like-
y to touch these hot areas.
Do not park the motorcycle on a
slope or soft ground, otherwise it 1
may fall over.
Do not park the motorcycle near
a flammable source, (e.g., a ker-
osene heater, or near an open
lame), otherwise it could catch
ire.
hen transporting the motorcycle
another vehicle, make sure that
s kept upright. If the motorcycle
ould lean over, gasoline may
ak out of the carburetor or fuel
nk.
you should swallow any gaso-
e, inhale a lot of gasoline vapor,
allow gasoline to get into your
es, see your doctor immediate-
If any gasoline spills on your
n or clothing, immediately wash
e affected area with soap and
ter and change your clothes.
1-4

EAU10381
y before operating this vehicle.
1-5

SAFETY INFORMATION
4
1-6

EAU10410
page 3-12)
(page 3-12)
2-1

DESCRIPTION
EAU10420
2-2

EAU10430
2-3

INSTRUMENT AND CONTROL FUNCTIONS
EAU10822 EAU11003
king) Indicator and warning lights
4
. 1. Neutral indicator light “NEUTRAL”
2. Turn signal indicator light “TURN”
3. Fuel level warning light “FUEL” 5
eter lighting, taillight and position 4. High beam indicator light “HIGH BEAM”
re on, but all other electrical sys- 5. Oil level warning light “OIL LEVEL”
re off. The key can be removed. 6
y must be pushed in from the EAU11040
position to be turned to “P”. Turn signal indicator light “TURN” 7

ECA11020
This indicator light flashes when the
ION: turn signal switch is pushed to the left or
8
use the parking position for right.
ended length of time, other-
he battery may discharge. EAU11070 9
Neutral indicator light “NEUTRAL”
This indicator light comes on when the
transmission is in the neutral position.
3-1

L FUNCTIONS
EAU32320 EAU11630
vel warning light “FUEL” Speedometer unit

rning light comes on when the
el drops below approximately
0.79 US gal) (0.66 Imp.gal).
his occurs, set the fuel reserve
o the “RES” position and refuel
as possible.
ctrical circuit of the warning light
checked according to the follow-
edure.
the engine stop switch to
UN” and turn the key to “ON”. 1. Tripmeter reset knob
ft the transmission into the neu- 2. Odometer
position or pull the clutch lever. 3. Tripmeter
sh the start switch. If the warn- The speedometer unit is equipped with
light does not come on, have a a speedometer, an odometer and a
maha dealer check the electri- tripmeter. The speedometer shows
circuit. 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.
3-2

EAU12171 EAU12343
ant temperature gauge Handlebar switches

Left
4
ant temperature gauge
ant temperature gauge red zone 1. Dimmer switch “LIGHTS”
2. Turn signal switch “TURN” 5
e key in the “ON” position, the 3. Horn switch “HORN”
temperature gauge indicates
mperature of the coolant. The Right 6
temperature varies with chang-
he weather and engine load. If 7
edle reaches or enters the red
stop the vehicle and let the en-
8
ol. (See page 6-40.)
ECA10020
ION: 9
t operate the engine if it is
ated.
1. Engine stop switch “ENGINE STOP”
2. Fuel reserve switch “FUEL”
3. Start switch “START”
3-3

L FUNCTIONS
EAU12510
witch “HORN” NOTE:

his switch to sound the horn. After switching to “RES”, approximately
3.0 L (0.79 US gal) (0.66 Imp.gal) of
EAU12650 fuel remain in the fuel tank.
stop switch “ENGINE STOP”
switch to “RUN” before starting
ine. Set this switch to “OFF” to
engine in case of an emergen-
h as when the vehicle overturns
the throttle cable is stuck.
EAU12690
witch “START”
is switch to crank the engine
starter.
ECA10050
ON:
ge 5-1 for starting instruc-
rior to starting the engine.
EAU12790
serve switch “FUEL”

normal operation, this switch
be kept in the “ON” position. If
warning light comes on while
et the switch to “RES”, refuel as
s possible, and then set the
back to “ON”.
3-4

EAU12870 EAU12890
pedal Brake lever
4
pedal 1. Brake lever
ift pedal is located on the left The brake lever is located at the right 5
the engine and is used in com- handlebar grip. To apply the front
n with the clutch lever when brake, pull the lever toward the handle-
the gears of the 5-speed con- bar grip. 6
mesh transmission equipped on
torcycle. 7
3-5

L FUNCTIONS
EAU13060
ank cap
ove the fuel tank cap
1. Unlock.
2. Insert the key into the lock, and

then turn it 1/4 turn clockwise. The
ng lever lock will be released and the fuel
tank cap can be removed.
sh the levers on the left and
ht side of the rider seat backrest To install the fuel tank cap
shown and slide the rider seat 1. Insert the fuel tank cap into the
ckrest forward. 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
3-6

EAU13210
fuel may deteriorate painted surfac-
es or plastic parts.
EAU13300
Recommended fuel:
UNLEADED GASOLINE ONLY 2
Fuel tank capacity:
15.0 L (3.96 US gal) (3.30 Imp.gal)
3
Fuel reserve amount:
3.0 L (0.79 US gal) (0.66 Imp.gal)
4
ank filler tube ECA11400
evel CAUTION:
Use only unleaded gasoline. The use 5
ure that there is sufficient fuel in
k. Fill the fuel tank to the bottom of leaded gasoline will cause severe
ller tube as shown. damage to internal engine parts, 6
EWA10880 such as the valves and piston rings,
ARNING as well as to the exhaust system. 7
o not overfill the fuel tank, oth- Your Yamaha engine has been de-
wise it may overflow when the signed to use regular unleaded gaso- 8
el warms up and expands. line with a pump octane number
oid spilling fuel on the hot en- [(R+M)/2] of 86 or higher, or a research
ne. octane number of 91 or higher. If 9
ECA10070 knocking (or pinging) occurs, use a
ION: gasoline of a different brand or premi-
iately wipe off spilled fuel um unleaded fuel. Use of unleaded fuel
clean, dry, soft cloth, since will extend spark plug life and reduce
3-7

L FUNCTIONS
EAU13630 EAU13730
r (choke) lever Steering lock
r (choke) lever (page 3-8) 1. Steering lock
a cold engine requires a richer To lock the steering

mixture, which is supplied by 1. Turn the handlebar all the way to
er (choke). the right.
e lever in direction (a) to turn on 2. Open the steering lock cover, and
er (choke). then insert the key.
e lever in direction (b) to turn off 3. Turn the key 1/8 turn counterclock-
er (choke). wise, push it in while turning the
handlebar slightly to the left, and
then turn the key 1/8 turn clock-
wise.
4. Check that the steering is locked,
remove the key, and then close the
lock cover.
3-8

EAU14230
seat
move the rider seat

lease the rider seat backrest by
shing the levers on the left and
ht side as shown, and then slide
2
e backrest forward.
3
1. Bolt
2. Screw
4
To install the rider seat
1. Insert the projection on the front of 5
the rider seat into the seat holder
as shown.
6
ing lever
7
move the bolts and screws, and
en pull the rider seat off. 8
1. Projection
2. Seat holder
3-9

L FUNCTIONS
EAU14281 EAU14660
et holder Adjusting the front fork

This front fork is equipped with air
valves for adjusting the spring rate.
EWA10180
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 vehicle on the centerstand.
et holder
k. NOTE:
When checking and adjusting the air
n the helmet holder, insert the
pressure, there should be no weight on
the lock, and then turn the key
the front end of the vehicle.
wn.
the helmet holder, place it in the 2. Remove the air valve cap from
position, and then remove the each fork leg.
EWA10160
ARNING
ide with a helmet attached to
met holder, since the helmet
objects, causing loss of con-
d possibly an accident.
3-10

a Yamaha dealer. 5. Securely install the air valve caps.
increase the spring rate and
ereby harden the suspension, in-
ease the air pressure with an air
mp or compressed air. To de-
ease the spring rate and thereby
ften the suspension, decrease 2
e air pressure by pushing each
ve stem down. 3
ng rate:
nimum/standard (soft): 4
Air pressure = 40 kPa (5.7 psi) (0.4
kgf/cm2)
aximum (hard): 5
Air pressure = 100 kPa (14 psi)
(1.0 kgf/cm2)
6
ECA10090
ION: 7
exceed the maximum air pres-
otherwise the front fork oil
8
may become damaged.
EWA11180
ARNING 9
must be no difference in air
re between the left and right
gs, otherwise poor handling
ss of stability may result.
3-11

L FUNCTIONS
justment.
preload
(a) (b)
Spring preload:
g preload adjusting ring Minimum (soft):
1
ease the spring preload and Standard:
harden the suspension, turn 1
usting ring on each shock ab- Maximum (hard):
assembly in direction (a). To de- 5
the spring preload and thereby
he suspension, turn the adjust-
on each shock absorber as-
in direction (b).
gn the bottom edge of the ad-

ing ring with the appropriate
ting on the shock absorber.
e the special wrench included in
owner’s tool kit to make this ad-
3-12

formance.
ping force: ● Always have a Yamaha dealer
nimum (soft):
1 service the shock absorbers.
andard:
1
aximum (hard):
4
2
EWA10230
ARNING
3
shock absorbers contain
pressurized nitrogen gas. For
handling read and under- 4
the following information be-
andling the shock absorbers. 5
anufacturer cannot be held re-
ble for property damage or
6
nal injury that may result from
per handling.
o not tamper with or attempt to 7
en the gas cylinders.
o not subject the shock ab- 8
rbers to an open flame or oth-
high heat sources, otherwise
9
ey may explode due to exces-
ve gas pressure.
o not deform or damage the
s cylinders in any way, as this
ll result in poor damping per-
3-13

L FUNCTIONS
EAU15301
ECA10181
ON: Sidestand
V-Boost operation cannot be The sidestand is located on the left side
when the main switch is of the frame. Raise the sidestand or
on, ask a Yamaha dealer to lower it with your foot while holding the
it. vehicle upright.
NOTE:
The built-in sidestand switch is part of
the ignition circuit cut-off system, which
cuts the ignition in certain situations.
(See further down for an explanation of
the ignition circuit cut-off system.)
EWA10240
WARNING
The vehicle must not be ridden with
the sidestand down, or if the side-
stand cannot be properly moved up
(or does not stay up), otherwise the
sidestand could contact the ground
and distract the operator, resulting
in a possible loss of control.
Yamaha’s ignition circuit cut-off
system has been designed to assist
the operator in fulfilling the respon-
sibility of raising the sidestand be-
fore starting off. Therefore, check
this system regularly as described
below and have a Yamaha dealer re-
3-14

EAU15321
on circuit cut-off system

ition circuit cut-off system (com-
the sidestand switch, clutch
and neutral switch) has the fol-
functions.
prevents starting when the trans-
2
ssion is in gear and the side-
and is up, but the clutch lever is
t pulled. 3
prevents starting when the trans-
ssion is in gear and the clutch le- 4
r is pulled, but the sidestand is
l down.
uts the running engine when the 5
nsmission is in gear and the sid-
tand is moved down. 6
cally check the operation of the
circuit cut-off system according 7
ollowing procedure.
EWA10260
ARNING 8
e vehicle must be placed on
e centerstand during this in- 9
ection.
a malfunction is noted, have a
maha dealer check the sys-
m before riding.
3-15

L FUNCTIONS
NOTE:
on.
This check is most reliable if performed with
a warmed-up engine.
The neutral switch may be defective.

The motorcycle should not be ridden until
checked by a Yamaha dealer.
The sidestand switch may be defective.

The clutch switch may be defective.

n.
3-16

PRE-OPERATION CHECKS
EAU15591
ibility. Vital components can start to deteriorate quickly and unexpectedly,

as a result of exposure to the elements). Any damage, fluid leakage or loss
ces. Therefore, it is very important, in addition to a thorough visual inspec-
e.
2
he vehicle is used. Such an inspection can be accomplished in a very short
n worth the time involved.
3
EWA11150
4
ot working properly, have it inspected and repaired before operating
4-1

EAU15603
CHECKS PAGE
uel tank.
3-7
akage.
gine.
commended oil to specified level. 6-11
leakage.
leakage. 6-14
in reservoir.
commended coolant to specified level. 6-15
m for leakage.
ve Yamaha dealer bleed hydraulic system.

y.
or wear. 6-24, 6-25

y.
eservoir.
commended brake fluid to specified level.
tem for leakage.

or wear.
y. 6-25
eservoir.
commended brake fluid to specified level.
tem for leakage.
4-2

PRE-OPERATION CHECKS
CHECKS PAGE

reservoir. 6-23, 6-25
ecommended fluid to specified level.
stem for leakage.
ration is smooth.
ay. 2
6-19, 6-27
Yamaha dealer adjust cable free play and lubricate cable
ration is smooth. 3
6-27
ary.
4
n and tread depth.
6-20, 6-22
y. 5
ration is smooth.
6-27
oting points if necessary.
ration is smooth. 6
6-28
ting points if necessary.
ration is smooth.
ecessary.
6-28 7
nuts, bolts and screws are properly tightened.
—
y. 8
—
y.
ignition circuit cut-off system. 9
3-14
e, have Yamaha dealer check vehicle.
6-31
ter if necessary.
4-3

NT RIDING POINTS
EAU32300
2. Shift the transmission into the neu-
ng and warming up a tral position.
ngine NOTE:
r for the ignition circuit cut-off When the transmission is in the neutral
to enable starting, one of the position, the neutral indicator light
g conditions must be met: should be on, otherwise have a
e transmission is in the neutral Yamaha dealer check the electrical cir-
sition. cuit.
e transmission is in gear with
clutch lever pulled and the sid- 3. Turn the starter (choke) on and
and up. completely close the throttle. (See
EWA10290 page 3-8.)
ARNING 4. Start the engine by pushing the
fore starting the engine, start switch.
eck the function of the igni- NOTE:
n circuit cut-off system ac- If the engine fails to start, release the
ding to the procedure start switch, wait a few seconds, and
scribed on page 3-15. then try again. Each starting attempt
ver ride with the sidestand should be as short as possible to pre-
wn. serve the battery. Do not crank the en-
n the key to “ON” and make gine more than 10 seconds on any one
e that the engine stop switch is attempt.
to “RUN”. ECA10230
ECA10220
CAUTION:
ON:
● The oil level warning light and
uel level warning light comes fuel level warning light should
ck the fuel level, and, if nec- come on when the start switch
refuel as soon as possible. is pushed, and they should go
5-1

RATION AND IMPORTANT RIDING POINTS
er starting the engine, move the EAU16640
arter (choke) back halfway. Starting a warm engine

ECA11130 Follow the same procedure as for start-
ION: ing a cold engine with the exception
aximum engine life, always that the starter (choke) is not required
the engine up before starting when the engine is warm.
ver accelerate hard when the 2
is cold!
hen the engine is warm, turn the 3
arter (choke) off.
4
gine is warm when it responds
y to the throttle with the starter
) turned off. To avoid the possi- 5
excessive exhaust emissions,
eave the starter (choke) on long- 6
necessary. The time necessary
ter (choke) use depends upon
7
mbient temperature. Tempera-
bove 10 °C (50 °F) require about
nds of starter (choke) use and 8
atures below 10 °C (50 °F) re-
bout 35 seconds with the starter 9
) turned on, then about 2.5 min-
th the starter (choke) in the half-
sition.
5-2

NT RIDING POINTS
ast for long periods of time quickly pull the clutch lever in.
h the engine off, and do not 5. Shift the transmission into second
w the motorcycle for long dis- gear. (Make sure not to shift the
ces. The transmission is transmission into the neutral posi-
operly lubricated only when tion.)
engine is running. Inade- 6. Open the throttle part way and
ate lubrication may damage gradually release the clutch lever.
transmission. 7. Follow the same procedure when
ways use the clutch while shifting to the next higher gear.
anging gears to avoid damag- NOTE:
the engine, transmission, Always shift gears at the recommended
d drive train, which are not shift points.
signed to withstand the
ock of forced shifting.
EAU16700
To decelerate
EAU16680
1. Apply both the front and the rear
t out and accelerate
brakes to slow the motorcycle.
l the clutch lever to disengage
2. Shift the transmission into first
clutch.
gear when the motorcycle reaches
ft the transmission into first
20 km/h (12.5 mi/h). If the engine is
ar. The neutral indicator light
about to stall or runs very roughly,
ould go out.
pull the clutch lever in and use the
en the throttle gradually, and at
brakes to stop the motorcycle.
same time, release the clutch
3. Shift the transmission into the neu-
er slowly.
tral position when the motorcycle
the recommended shift points
is almost completely stopped. The
own in the following table, close
neutral indicator light should come
throttle, and at the same time,
on.
5-3

RATION AND IMPORTANT RIDING POINTS
EAU16841
be changed, and the oil filter car-
ne break-in tridge or element replaced.
s never a more important period
fe of your engine than the period 1600 km (1000 mi) and beyond
n 0 and 1600 km (1000 mi). For The vehicle can now be operated nor-
son, you should read the follow- mally.
ECA10310
erial carefully. CAUTION: 2
he engine is brand new, do not
● Keep the engine speed out of
excessive load on it for the first
the tachometer red zone. 3
m (1000 mi). The various parts in
● If any engine trouble should oc-
gine wear and polish themselves
cur during the engine break-in
correct operating clearances. 4
period, immediately have a
this period, prolonged full-throt-
Yamaha dealer check the vehi-
ation or any condition that might
cle. 5
n engine overheating must be
d.
6
EAU17121
7
0 km (0–600 mi)
prolonged operation above 4500
8
1600 km (600–1000 mi)
prolonged operation above 5500 9
ECA10331
ION:
000 km (600 mi) of operation,
gine oil and final gear oil must
5-4

NT RIDING POINTS
5-5

ODIC MAINTENANCE AND MINOR REPAIR
EAU17301 EAU17551
ODIC MAINTENANCE Owner’s tool kit

ER PERIODIC MAINTENANCE
UR VEHICLE IS IMPORTANT
DER TO ENJOY LONG, PLEA-
BLE SERVICE. ESPECIALLY
TANT ARE THE MAINTE-
2
E SERVICES RELATED TO
IONS CONTROL. THESE
ROLS NOT ONLY FUNCTION 3
NSURE CLEANER AIR, BUT
LSO VITAL TO PROPER EN- 4
OPERATION AND MAXIMUM 1. Owner’s tool kit
ORMANCE. IN THE FOLLOW- 2. Rider backrest
PERIODIC MAINTENANCE 5
The tool kit is located inside the storage
TS, THE SERVICES RELATED compartment behind the rider seat
MISSIONS CONTROL ARE backrest. (See page 3-9.) 6
PED SEPARATELY. THESE
CES REQUIRE SPECIALIZED 7
KNOWLEDGE, AND EQUIP-
YAMAHA DEALERS ARE
ED AND EQUIPPED TO PER- 8
THESE PARTICULAR SER-
9
The service information included in this

manual and the tools provided in the
6-1

ND MINOR REPAIR
6-2

EAU17600
mission control system

INITIAL ODOMETER READINGS
600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
2
cks or
√ √ √ √ √
3
Replace.
4
√ Replace. √ Replace. √
13000
lear-
5
Every 26600 mi (42000 km)
d.
cracks 6
√ √ √ √ √
carbu-
√ √ √ √ √ √
7
idle
√ √ √ √ √ 8
√ √ √ √ √
9
essary.
dam-
√ √
skills, have a Yamaha dealer perform the service.
6-3

ND MINOR REPAIR
EAU32183
chart
600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
r.
√ √ √ √ √
d
opera- √ √ √ √ √
leak-
√ √ √ √ √ √
el, and
√ √ √ √ √ √
es-
el, and
√ √ √ √ √ √
es-
ge. √ √ √ √ √
Every 4 years
age.
√ √ √ √ √
dam-
√ √ √ √ √
6-4

600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
th
√ √ √ √ √
2
es for
√ Repack. 3
th-
es for 4
th-
√ √ √ √ Repack. √ 5
every
24
and fas-
6
√ √ √ √ √
7
d
se) √ √ √ √ √
8
d
se) √ √ √ √ √
9
d
√ √ √ √ √
se)
6-5

ND MINOR REPAIR
600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
ace if
√ √ √ √ √ √
il leak-
√ √ √ √ √
il leak-
√ √ √ √ √
ore
√ √ √ √ √ √
√ √ √
dam-
√ √ √ √ √
col
24 Change.
eak-
1000
Change. √ √ √ Change. √
after
m) or
cable
thor- √ √ √ √ √ √
6-6

600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi
(1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km)
or or or or or or
e play.
ree
√ √ √ √ √
2
hous-
3
skills, have a Yamaha dealer perform the service.
4
the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
EAU17660
5
6
ou are riding in unusually wet or dusty areas.
7
aster cylinders, caliper cylinders or clutch release cylinder, always change
utch fluid levels and fill the reservoirs as required. 8
the brake or clutch master cylinders, caliper cylinders and clutch release
four years or if cracked or damaged. 9
6-7

ND MINOR REPAIR
3. Push down on the rear of the cowl-
ing until it locks in place.
4. Remove the key from the lock.
EAU19180
Panel A
To remove the panel

1. Remove cowling A. (See
page 6-8.)
k. 2. Remove the screws, and then take
the panel off.
l the cowling off as shown.
ll the cowling
e holders under the cowling with
ections on the frame.
1. Screw
To install the panel

1. Place the panel in the original po-
sition, and then install the screws.
r 2. Install the cowling.
tion
6-8

EAU19543
king the spark plugs

ark plugs are important engine
nents, which are easy to check.
heat and deposits will cause any
plug to slowly erode, the spark
hould be removed and checked
2
rdance with the periodic mainte-
and lubrication chart. In addition,
dition of the spark plugs can re- 3
e condition of the engine. 1. Spark plug wrench
To check the spark plugs 4

move a spark plug
1. Check that the porcelain insulator
move the spark plug cap.
around the center electrode on 5
each spark plug is a medi-
um-to-light tan (the ideal color
6
when the vehicle is ridden normal-
ly).
2. Check that all spark plugs installed 7
in the engine have the same color.
NOTE: 8
If any spark plug shows a distinctly dif-
ferent color, the engine could be defec- 9
k plug cap tive. Do not attempt to diagnose such
problems yourself. Instead, have a
move the spark plug as shown,
Yamaha dealer check the vehicle.
h the spark plug wrench includ-
in the owner’s tool kit. 3. Check each spark plug for elec-
6-9

ND MINOR REPAIR
n wipe off any grime from the EAU19672
ark plug threads. Canister (for California only)

tall the spark plug with the
ark plug wrench, and then tight-
it to the specified torque.
ening torque:
ark plug:
18 Nm (1.8 m·kgf, 13 ft·lbf)
ue wrench is not available when

g a spark plug, a good estimate
correct torque is 1/4–1/2 turn
ger tight. However, the spark
ould be tightened to the speci-
ue as soon as possible.
This model is equipped with a canister
tall the spark plug cap.
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.
6-10

2. Place an oil pan under the engine
to collect the used oil.
gine oil should be between the 3. Remove the engine oil filler cap
m and maximum level marks. and drain bolt to drain the oil from
the crankcase.
5
ne oil level check window
mum level mark 1. Engine oil filler cap
mum level mark 6
he engine oil is below the mini-
um level mark, add sufficient oil 7
the recommended type to raise
o the correct level. 8
nge the engine oil (with or

t oil filter cartridge replace- 9
art the engine, warm it up for

veral minutes, and then turn it
.
6-11

ND MINOR REPAIR
er cartridge 1. O-ring
er wrench
NOTE:
Make sure that the O-ring is properly
ilter wrench is available at a seated.
a dealer.
6. Install the new oil filter cartridge
ply a thin coat of engine oil to with an oil filter wrench, and then
O-ring of the new oil filter car- tighten it to the specified torque
ge. with a torque wrench.
6-12

ommended engine oil: NOTE:
e page 8-1. After the engine is started, the engine
uantity: oil level warning light should go off if the
thout oil filter cartridge replace-
oil level is sufficient.
ent:
3.50 L (3.70 US qt) (3.08 Imp.qt) ECA10400
th oil filter cartridge replacement: CAUTION:

3.80 L (4.02 US qt) (3.34 Imp.qt) 2
If the oil level warning light flickers
ECA11620 or remains on, immediately turn the
ION: engine off and have a Yamaha dealer 3
order to prevent clutch slip- check the vehicle.
ge (since the engine oil also 4
10. Turn the engine off, and then
bricates the clutch), do not check the oil level and correct it if
x any chemical additives. Do necessary. 5
t use oils with a diesel speci-
ation of “CD” or oils of a high-
quality than specified. In 6
dition, do not use oils labeled
NERGY CONSERVING II” or 7
gher.
ake sure that no foreign mate- 8
l enters the crankcase.
art the engine, and then let it idle 9
several minutes while checking
or oil leakage. If oil is leaking, im-
ediately turn the engine off and
eck for the cause.
6-13

ND MINOR REPAIR
move the oil filler bolt, and then 2. Remove the oil filler bolt and drain
eck the oil level in the final gear bolt to drain the oil from the final
e. gear case.
3. Install the final gear oil drain bolt,
evel should be at the brim of the and then tighten it to the specified
e. torque.
Tightening torque:
Final gear oil drain bolt:
23 Nm (2.3 m·kgf, 17 ft·lbf)
4. Add the recommended final gear

oil to the brim of the filler hole.
Recommended final gear oil:

Hypoid gear oil SAE 80 (API GL4) or
multi-grade hypoid gear oil SAE
80W-90
Oil quantity:
gear oil filler bolt
0.20 L (0.21 US qt) (0.18 Imp.qt)
ct oil level
gear oil drain bolt
NOTE:
he oil is below the brim of the fill- GL4 is a quality rating. Hypoid gear oils
hole, add sufficient oil of the rec- rated GL5 or GL6 may also be used.
mended type to raise it to the
rect level. 5. Install and tighten the filler bolt.
6. Check the final gear case for oil
nge the final gear oil leakage. If oil is leaking, check for
ce an oil pan under the final the cause.
ar case to collect the used oil.
6-14

ECA10470
CAUTION:
oolant should be between the
● If coolant is not available, use
m and maximum level marks.
distilled water or soft tap water
instead. Do not use hard water
or salt water since it is harmful
to the engine. 2
● If water has been used instead
of coolant, replace it with cool-
3
ant as soon as possible, other-
wise the engine may not be
sufficiently cooled and the cool- 4
ing system will not be protected
against frost and corrosion. 5
mum level mark ● If water has been added to the
mum level mark
coolant, have a Yamaha dealer
check the antifreeze content of 6
the coolant is at or below the
nimum level mark, remove the the coolant as soon as possible,
olant reservoir cap and add otherwise the effectiveness of 7
olant to the maximum level the coolant will be reduced.
ark. EWA10380 8
stall the coolant reservoir cap WARNING
d the cowling. Never attempt to remove the radiator 9
cap when the engine is hot.
ant reservoir capacity (up to the
mum level mark):
30 L (0.32 US qt) (0.26 Imp.qt)
NOTE:
● The radiator fan is automatically
switched on or off according to the
6-15

ND MINOR REPAIR
tor cap 1. Water pump drain bolt
n the coolant drain cock, mak- 7. Remove the cylinder drain plug
sure to align the “ON” with the covers on the outside of the cylin-
sition indicator. der blocks by removing the
screws.
nt drain cock
on indicator 1. Screw
move the water pump drain bolt 8. Remove the rubber coolant drain
drain the water pump housing. plugs to drain the coolant from the
6-16

ain plug covers. distilled water or soft tap water
instead. Do not use hard water
the rubber plugs for damage or salt water since it is harmful
place them if necessary. to the engine.
● If water has been used instead
rn the coolant drain cock, mak- of coolant, replace it with cool-
g sure to align the “OFF” with the ant as soon as possible, other- 2
sition indicator. wise the engine may not be
ur the recommended coolant sufficiently cooled and the cool-
o the reservoir to the maximum ing system will not be protected 3
el, and then install the cap. against frost and corrosion.
ur the recommended coolant ● If water has been added to the 4
o the radiator until it is full. coolant, have a Yamaha dealer
check the antifreeze content of
reeze/water mixture ratio: 5
1
the coolant as soon as possible,
ommended antifreeze: otherwise the effectiveness of
gh-quality ethylene glycol anti- the coolant will be reduced. 6
eze containing corrosion inhibitors
aluminum engines 15. Install the radiator cap, start the
ant quantity: engine, let it idle for several min- 7
adiator capacity (including all utes, and then turn it off.
utes): 16. Remove the radiator cap to check 8
2.75 L (2.91 US qt) (2.42 Imp.qt)
the coolant level in the radiator. If
oolant reservoir capacity (up to the
aximum level mark): necessary, add sufficient coolant
9
0.30 L (0.32 US qt) (0.26 Imp.qt) until it reaches the top of the radia-
tor, and then install the radiator
ECA10470
cap.
ION: 17. Check the coolant level in the res-
coolant is not available, use ervoir. If necessary, remove the
6-17

ND MINOR REPAIR
EAU20510
ing the air filter element

ilter element should be cleaned
tervals specified in the periodic
ance and lubrication chart.
he air filter element more fre-
if you are riding in unusually
usty areas.
move cowling A. (See
ge 6-8.)
move the air filter case cover by 1. Air filter element
moving the screws.
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.
ECA10480
CAUTION:
● Make sure that the air filter ele-
ment is properly seated in the
l the air filter element out. air filter case.
● The engine should never be op-
erated without the air filter ele-
ment installed, otherwise the
piston(s) and/or cylinder(s) may
6-18

EAU21271 EAU21381
uretors Checking the throttle cable

rburetors are important parts of free play
gine and emission control sys-
hich require very sophisticated
ment. Therefore, all carburetor
ments should be left to a Yamaha
2
who has the necessary profes-
knowledge and experience.
3
1. Throttle cable free play

5
The throttle cable free play should mea-
sure 3.0–5.0 mm (0.12–0.20 in) at the
6
throttle grip. Periodically check the
throttle cable free play and, if neces-
sary, have a Yamaha dealer adjust it. 7
6-19

ND MINOR REPAIR
EAU32380
Tire air pressure (measured on cold

mize the performance, durabil- tires):
0–90 kg (0–198 lb):
safe operation of your motorcy- Front:
e the following points regarding 225 kPa (33 psi) (2.25 kgf/cm2)
cified tires. Rear:
pressure 225 kPa (33 psi) (2.25 kgf/cm2)
air pressure should be checked 90–215 kg (198–474 lb) (CAL)(ZAF)
90–216 kg (198–476 lb) (U49):
ecessary, adjusted before each Front:
225 kPa (33 psi) (2.25 kgf/cm2)
EWA10500
Rear:
ARNING 250 kPa (36 psi) (2.50 kgf/cm2)
e tire air pressure must be Maximum load*:
215 kg (474 lb) (CAL)(ZAF)
ecked and adjusted on cold
216 kg (476 lb) (U49)
s (i.e., when the temperature * Total weight of rider, passenger, car-
the tires equals the ambient go and accessories
mperature).
EWA10510
e tire air pressure must be ad-
WARNING
ted in accordance with the
ng speed and with the total Proper loading of your vehicle is im-
ight of rider, passenger, car- portant for several characteristics of
and accessories approved your vehicle, such as handling,
this model. braking, performance and safety. Do
not carry loosely packed items that
can shift. Securely pack your heavi-
est items close to the center of the
vehicle, and distribute the weight
evenly from side to side. Properly
adjust the suspension for your load,
6-20

ise lines (minimum tread depth), EWA10460
re has a nail or glass fragments WARNING

if the sidewall is cracked, con- ● The front and rear tires should
Yamaha dealer immediately and be of the same make and de-
e tire replaced. sign, otherwise the handling
characteristics of the vehicle
mum tire tread depth (front and
: cannot be guaranteed. 2
0 mm (0.04 in) ● After extensive tests, only the
tires listed below have been ap-
EWA10580 3
proved for this model by
ARNING Yamaha Motor Co., Ltd.
is dangerous to ride with a 4
orn-out tire. When a tire tread Front tire:
gins to show crosswise lines, Size: 5
ve a Yamaha dealer replace 110/90-18M/C 61V
e tire immediately. Manufacturer/model:
BRIDGESTONE/G525 6
e replacement of all wheel- DUNLOP/F20
d brake-related parts, includ- Rear tire:
g the tires, should be left to a Size: 7
maha dealer, who has the 150/90-15M/C 74V
cessary professional knowl- Manufacturer/model:
BRIDGESTONE/G526 8
ge and experience. DUNLOP/K525
EWA10600 9
formation
WARNING
otorcycle is equipped with tube-
es, and cast wheels. This motorcycle is fitted with su-
per-high-speed tires. Note the fol-
lowing points in order to make the
6-21

ND MINOR REPAIR
EAU21981
wheels
mize the performance, durabil-
safe operation of your motorcy-
e the following points regarding
cified wheels.
e wheel rims should be checked
cracks, bends, warpage or 1
mage before each ride. If any 2
mage is found, have a Yamaha
aler replace the wheel. Do not 1. Valve stem nut
empt even the smallest repair to 2. Valve stem locknut
wheel. A deformed or cracked
Tightening torques:
eel must be replaced.
Valve stem nut:
e wheel should be balanced 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
enever either the tire or wheel Valve stem locknut:
s been changed or replaced. An 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf)
balanced wheel can result in
or performance, adverse han-
g characteristics, and a short-
ed tire life.
e at moderate speeds after
anging a tire since the tire sur-
e must first be “broken in” for it
develop its optimal characteris-
.
er repairing or replacing a tire,
hten the valve stem nut and
knut to the specified torques.
6-22

pproved by Yamaha. EAU22072
Clutch lever
Since this model is equipped with a hy-
draulic clutch, adjusting the clutch lever
free play is not needed. However, it is
necessary to check the clutch fluid level
and check the hydraulic system for
2
leakage before each ride. If the clutch
lever free play does become excessive,
and shifting becomes rough or clutch 3
slippage occurs, causing poor acceler-
ation, there may be air in the clutch sys- 4
tem. If there is air in the hydraulic
system, have a Yamaha dealer bleed
the system before operating the motor- 5
cycle.
6
6-23

ND MINOR REPAIR
hten the locknut. EAU22270
EWA10630 Adjusting the rear brake light

ARNING switch
er adjusting the brake lever
e play, check the free play
d make sure that the brake is
rking properly.
soft or spongy feeling in the
ke lever can indicate the
sence of air in the hydraulic
stem. If there is air in the hy-
ulic system, have a Yamaha
aler bleed the system before
erating the motorcycle. Air in 1. Rear brake light switch
hydraulic system will dimin- 2. Rear brake light switch adjusting nut
the braking performance, The rear brake light switch, which is ac-
ich may result in loss of con- tivated by the brake pedal, is properly
l and an accident. 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).
6-24

EAU22680
Clutch
king the brake and clutch
evels
brake
1. Minimum level mark

4
Insufficient brake fluid may allow air to
enter the brake or clutch systems, pos- 5
sibly causing them to become ineffec-
mum level mark
tive.
rake Before riding, check that the brake fluid 6
is above the minimum level mark and
replenish if necessary. A low brake fluid 7
level may indicate worn brake pads
and/or brake system leakage. If the
8
brake level is low, be sure to check the
brake pads for wear and the brake sys-
tem for leakage. 9
NOTE:
The rear brake fluid reservoir is located
B behind panel B. (See page 6-8.)
mum level mark
Observe these precautions:
6-25

ND MINOR REPAIR
he fluid and may result in vapor EAU22750
k. Changing the brake and

ke fluid may deteriorate paint- clutch fluids
surfaces or plastic parts. Al- Have a Yamaha dealer change the
ys clean up spilled fluid brake and clutch fluids at the intervals
mediately. specified in the NOTE after the periodic
the brake pads wear, it is nor- maintenance and lubrication chart. In
l for the brake fluid level to grad- addition, have the oil seals of the brake
y go down. However, if the and clutch master cylinders and cali-
ke fluid level goes down sud- pers as well as the brake and clutch
nly, have a Yamaha dealer hoses replaced at the intervals listed
eck the cause. below or whenever they are damaged
or leaking.
● Oil seals: Replace every two
years.
● Brake and clutch hoses: Replace
every four years.
6-26

EAU23111 EAU23131
king and lubricating the Checking and lubricating the

le grip and cable brake and shift pedals
eration of the throttle grip should
cked before each ride. In addi-
e cable should be lubricated at
ervals specified in the periodic 2
nance chart.
The operation of the brake and shift 9

pedals should be checked before each
ride, and the pedal pivots should be lu-
bricated if necessary.
6-27

ND MINOR REPAIR
EAU23140 EAU23211
king and lubricating the Checking and lubricating the

and clutch levers centerstand and sidestand
eration of the brake and clutch The operation of the centerstand and
hould be checked before each sidestand should be checked before
d the lever pivots should be lu- each ride, and the pivots and met-
if necessary. al-to-metal contact surfaces should be
lubricated if necessary.
mmended lubricant: EWA10740
hium-soap-based grease (all-pur- WARNING
se grease)
If the centerstand or sidestand does
not move up and down smoothly,
have a Yamaha dealer check or re-
pair it.
Recommended lubricant:
Lithium-soap-based grease (all-pur-
pose grease)
6-28

EAU23271
king the front fork

ndition and operation of the front
ust be checked as follows at the
s specified in the periodic main-
e and lubrication chart.
2
ck the condition
EWA10750
ARNING 3
ely support the vehicle so that ECA10590
s no danger of it falling over. CAUTION:

4
If any damage is found or the front
the inner tubes for scratches,
fork does not operate smoothly,
e and excessive oil leakage. 5
have a Yamaha dealer check or re-
pair it.
ck the operation
6
ace the vehicle on a level sur-
ce and hold it in an upright posi-
n. 7
hile applying the front brake,
sh down hard on the handlebars 8
veral times to check if the front
k compresses and rebounds
moothly. 9
6-29

ND MINOR REPAIR
EAU23290
Checking the wheel bearings

The front and rear wheel bearings must
be checked at the intervals specified in
the periodic maintenance and lubrica-
tion 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.
6-30

up when checking the electro- lead and the starter motor lead
el. from the starter motor relay.
eck the electrolyte level in the
ttery.
ectrolyte should be between the

2
m and maximum level marks.
4
1. Starter motor lead (black)
2. Positive battery lead (red)
3. Negative battery lead 5
7. Disconnect the couplers shown.

8. Remove the ignition coil assem- 6
blies by removing the bolts.
mum level mark 7
mum level mark
he electrolyte is at or below the 8

nimum level mark, continue with
e following steps. 9
move the rider seat. (See
ge 3-9.)
sconnect the negative battery
ad from the battery.
sconnect the positive battery
6-31

ND MINOR REPAIR
of water.
NTERNAL: Drink large quan-
ities of water or milk and im-
mediately call a physician.
EYES: Flush with water for 15
minutes and seek prompt
medical attention.
tteries produce explosive hy-
ogen gas. Therefore, keep
arks, flames, cigarettes, etc.,
ay from the battery and pro- 1. Battery
e sufficient ventilation when 2. Battery breather hose
3. Pass through the cable guide.
arging it in an enclosed
ace. 11. Install the ignition coil assemblies
EP THIS AND ALL BATTER- by installing the bolts.
S OUT OF THE REACH OF 12. Connect the couplers.
ILDREN. 13. Connect and tighten the positive
ECA10610 battery lead and the starter motor
ON: lead to the starter motor relay.
EWA10780
y distilled water, as tap water
WARNING
s minerals that are harmful
battery. Pass the positive battery lead and
starter lead through the hole in the
eck and, if necessary, correct ignition coil bracket as shown. Im-
breather hose routing. 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.
6-32

er installation, make sure that EAU23570
e battery leads are properly con- Replacing the fuses

cted to the battery terminals and The main fuse box is located under the
at the breather hose is properly rider seat. (See page 3-9.)
uted, in good condition, and not
structed.
ECA10600
2
ION:
breather hose is positioned in
a way that the frame is ex- 3
to electrolyte or gas expelled
he battery, the frame could 4
structural and external dam-
1. Main fuse 5
2. Spare main fuse
The fuse box, which contains the fuses 6

for the individual circuits, is located un-
der cowling A. (See page 6-8.) 7
6-33

ND MINOR REPAIR
EAU23780
fied fuses: Replacing the headlight bulb

in fuse: This model is equipped with a quartz
30.0 A
adlight fuse: bulb headlight. If the headlight bulb
15.0 A burns out, replace it as follows.
naling system fuse: 1. Remove the headlight unit by re-
10.0 A moving the screws.
diator fan fuse:
10.0 A
ition fuse:
10.0 A
ECA10640
ON:
use a fuse of a higher amper-
ting than recommended to
ausing extensive damage to
ctrical system and possibly a
1. Screw
n the key to “ON” and turn on 2. Disconnect the headlight coupler,

electrical circuit in question to and then remove the bulb cover.
eck if the device operates.
the fuse immediately blows
ain, have a Yamaha dealer
eck the electrical system.
6-34

herwise the transparency of EAU24281
ss, the luminosity of the bulb, Replacing a turn signal light

e bulb life will be adversely af- bulb or the tail/brake light bulb
Thoroughly clean off any dirt 1. Remove the lens by removing the
ngerprints on the headlight screws.
sing a cloth moistened with al-
or thinner. 2
5
1. Screw
6
ot touch the glass part of the bulb.
7
stall the headlight bulb cover,
d then connect the coupler.
stall the headlight unit by install- 8
g the screws.
ve a Yamaha dealer adjust the 9
adlight beam if necessary.
1. Turn signal light bulb
6-35

ND MINOR REPAIR
EAU24360
wheel
EAU24430
ove the front wheel

EWA10820
ARNING
s advisable to have a Yamaha
aler service the wheel.
curely support the motorcy-
so that there is no danger of 1. Speedometer cable
alling over. 2. Bolt
ce the motorcycle on the cen- 3. Front wheel axle pinch bolt
4. Wheel axle
stand.
connect the speedometer ca- 5. Pull the wheel axle out, and then
from the front wheel. remove the wheel.
move the brake calipers by re-
ving the bolts. EAU24842
ECA11060 To install the front wheel

ON: 1. Install the speedometer gear unit
pull the brake lever after the into the wheel hub so that the pro-
caliper has been removed, jections mesh with the slots.
se the brake pads will be
shut.
osen the front wheel axle pinch
t, then the wheel axle.
6-36

stall the brake calipers by install- EAU25080
g the bolts. Rear wheel

EAU37960
ure that there is enough space To remove the rear wheel
n the brake pads before install- EWA10820
brake calipers onto the brake WARNING

● It is advisable to have a Yamaha 2
ke the motorcycle off the center- dealer service the wheel.
● Securely support the motorcy- 3
and so that the front wheel is on
e ground. cle so that there is no danger of
ghten the wheel axle, then the it falling over.
4
nt wheel axle pinch bolt and the 1. Remove the axle nut, and then
ake caliper bolts to the specified loosen the rear wheel axle pinch
5
ques. bolt.
tening torques: 6
heel axle:
58 Nm (5.8 m·kgf, 42 ft·lbf)
ont wheel axle pinch bolt: 7
20 Nm (2.0 m·kgf, 14 ft·lbf)
ake caliper bolt:
40 Nm (4.0 m·kgf, 29 ft·lbf) 8
nnect the speedometer cable.

9
sh down hard on the handlebar
veral times to check for proper 1. Axle nut
k operation.
6-37

ND MINOR REPAIR
7. Pull the wheel to the right to sepa-
2 rate it from the final gear case, and
then remove it.
ECA11180
CAUTION:
Do not push the brake pedal after
3 the wheel has been removed togeth-
er with the brake disc, otherwise the
4 brake pads will be forced shut.
EAU37970
torque rod To install the rear wheel
1. Apply a light coating of lithi-
r
caliper bracket
um-soap-based grease to the
splines of the final gear case and
ile supporting the rear wheel, wheel hub.
the wheel axle out.
2. Install the wheel, brake caliper

move the brake caliper bracket bracket, spacer and wheel axle.
d spacer. 3. Install the brake caliper by install-
6-38

EAU25870
bleshooting
gh Yamaha motorcycles receive
ugh inspection before shipment
e factory, trouble may occur dur-
eration. Any problem in the fuel,
ession, or ignition systems, for
2
e, can cause poor starting and
power.
llowing troubleshooting charts 3
ent quick and easy procedures
cking these vital systems your- 4
owever, should your motorcycle
any repair, take it to a Yamaha
whose skilled technicians have 5
cessary tools, experience, and
ow to service the motorcycle 6
y.
nly genuine Yamaha replace- 7
arts. Imitation parts may look like
a parts, but they are often inferi-
e a shorter service life and can 8
expensive repair bills.
9
6-39

ND MINOR REPAIR
EAU25941
e
EWA10840
ile checking or working on the fuel system.
heck the compression.
The engine does not start.

upply fuel.
Check the compressoin.
Check the ignition.
Have a Yamaha dealer

check the vehicle.
h a dry cloth and correct the Open the throttle halfway and operate
aps, or replace the spark plugs. the electric starter.

maha dealer check the vehicle.
Check the battery.
battery is good.
Have a Yamaha dealer
k the electrolyte and battery check the vehicle.
connections, and charge the
ry if necessary.
6-40

EWA10400
e engine and radiator are hot. Scalding hot fluid and steam may be
ause serious injury. Be sure to wait until the engine has cooled.
bolt, place a thick rag, like a towel, over the radiator cap, and then
the detent to allow any residual pressure to escape. When the hissing 2
ap while turning it counterclockwise, and then remove the cap.
There is Have a Yamaha dealer check 3

The coolant level is low. leakage. and repair the cooling system.
Check the cooling system
for leakage.
There is
4
Add coolant. (See NOTE.)
no leakage.
5
The coolant level Start the engine. If the engine overheats again, have a
is OK. Yamaha dealer check and repair the cooling system.
6
arily used instead, provided that it is changed to the recommended coolant 7
6-41

TORAGE
s onto seals, gaskets and wheel thinner, fuel (gasoline), rust re-
es. Always rinse the dirt and de- movers or inhibitors, brake flu-
aser off with water. id, antifreeze or electrolyte.
● Do not use high-pressure wash-
ng ers or steam-jet cleaners since
ECA10770
they cause water seepage and
ON: deterioration in the following ar-
oid using strong acidic wheel eas: seals (of wheel and swing-
aners, especially on spoked arm bearings, fork and brakes),
eels. If such products are electric components (couplers,
ed on hard-to-remove dirt, do connectors, instruments,
leave the cleaner on the af- switches and lights), breather
ted area any longer than in- hoses and vents.
ucted. Also, thoroughly rinse ● For motorcycles equipped with
area off with water, immedi- a windshield: Do not use strong
ly dry it, and then apply a cor- cleaners or hard sponges as
ion protection spray. they will cause dulling or
proper cleaning can damage scratching. Some cleaning com-
ndshields, cowlings, panels pounds for plastic may leave
d other plastic parts. Use only scratches on the windshield.
soft, clean cloth or sponge Test the product on a small hid-
h mild detergent and water to den part of the windshield to
an plastic. make sure that it does not leave
not use any harsh chemical any marks. If the windshield is
oducts on plastic parts. Be scratched, use a quality plastic
e to avoid using cloths or polishing compound after
onges which have been in washing.
ntact with strong or abrasive
aning products, solvent or
7-1

MOTORCYCLE CARE AND STORAGE
before storing or covering it.
EWA11130
er drying the motorcycle, apply WARNING
corrosion protection spray on all
● Make sure that there is no oil or
etal, including chrome- and nick-
wax on the brakes or tires.
plated, surfaces to prevent cor-
● If necessary, clean the brake
sion.
discs and brake linings with a 2
regular brake disc cleaner or ac-
leaning
etone, and wash the tires with
y the motorcycle with a chamois 3
warm water and a mild deter-
an absorbing cloth.
gent. Before riding at higher
e a chrome polish to shine
speeds, test the motorcycle’s 4
rome, aluminum and stain-
braking performance and cor-
s-steel parts, including the ex-
nering behavior.
ust system. (Even the thermally 5
ECA10800
duced discoloring of stain-
s-steel exhaust systems can be CAUTION:
6
moved through polishing.) ● Apply spray oil and wax spar-
prevent corrosion, it is recom- ingly and make sure to wipe off
ended to apply a corrosion pro- any excess. 7
ction spray on all metal, ● Never apply oil or wax to any
luding chrome- and nickel-plat- rubber and plastic parts, but 8
, surfaces. treat them with a suitable care
e spray oil as a universal clean- product.
9
to remove any remaining dirt. ● Avoid using abrasive polishing
uch up minor paint damage compounds as they will wear
used by stones, etc. away the paint.
ax all painted surfaces.
t the motorcycle dry completely
7-2

TORAGE
EAU26230
“OFF”.
ge 3. Drain the carburetor float cham-
bers by loosening the drain bolts;
erm this will prevent fuel deposits from
store your motorcycle in a cool, building up. Pour the drained fuel
ce and, if necessary, protect it into the fuel tank.
dust with a porous cover. 4. Fill up the fuel tank and add fuel
ECA10810
stabilizer (if available) to prevent
ON: the fuel tank from rusting and the
oring the motorcycle in a fuel from deteriorating.
orly ventilated room or cover- 5. Perform the following steps to pro-
it with a tarp, while it is still tect the cylinders, piston rings, etc.
t, will allow water and humid- from corrosion.
to seep in and cause rust. a. Remove the spark plug caps
prevent corrosion, avoid and spark plugs.
mp cellars, stables (because b. Pour a teaspoonful of engine oil
the presence of ammonia) into each spark plug bore.
d areas where strong chemi- c. Install the spark plug caps onto
s are stored. the spark plugs, and then place
the spark plugs on the cylinder
erm head so that the electrodes are
storing your motorcycle for sev- grounded. (This will limit spark-
nths: ing during the next step.)
low all the instructions in the d. Turn the engine over several
are” section of this chapter. times with the starter. (This will
motorcycles equipped with a coat the cylinder walls with oil.)
l cock that has an “OFF” posi- e. Remove the spark plug caps
n: Turn the fuel cock lever to from the spark plugs, and then
7-3

MOTORCYCLE CARE AND STORAGE
an 0 °C (30 °F) or more than
°C (90 °F)]. For more informa-
n on storing the battery, see
ge 6-31.
any necessary repairs before

the motorcycle. 2
7-4

ation system: With oil filter cartridge replacement:
sump 3.80 L (4.02 US qt) (3.34 Imp.qt)
oil: Final gear oil:
Type:
E10W30 or SAE10W40 or SAE15W40 SAE80 API GL-4 Hypoid gear oil
AE20W40 or SAE20W50 (ZAF) Quantity:
MALUBE 4, SAE10W30 or SAE20W40 0.20 L (0.21 US qt) (0.18 Imp.qt)
L)(U49) Cooling system:
Coolant reservoir capacity (up to the maxi-
F mum level mark):
0 10 20 30 40 50 ˚C 0.30 L (0.32 US qt) (0.26 Imp.qt)
Radiator capacity (including all routes):
SAE 10W-30 2.75 L (2.91 US qt) (2.42 Imp.qt)
SAE 10W-40
Air filter:
Air filter element:
SAE 15W-40 Dry element
SAE 20W-40 Fuel:
Recommended fuel:
SAE 20W-50 Regular unleaded gasoline only (ZAF)
Unleaded gasoline only (CAL)(U49)
9, CAL
Fuel tank capacity:
30° 50° 70° 90° 110° 130°F
15.0 L (3.96 US gal) (3.30 Imp.gal)
MALUBE 4 (10W30) Fuel reserve amount:
AE 10W30 3.0 L (0.79 US gal) (0.66 Imp.gal)
Carburetor:
YAMALUBE 4 (20W40)
or SAE 20W40 Manufacturer:
MIKUNI
0° 10° 20° 30° 40° 50°C Type × quantity:
BDS35 x 4
mended engine oil grade:
service SE, SF, SG type or higher
Spark plug (s):
Manufacturer/model:
oil quantity:
NGK/DPR8EA-9
t oil filter cartridge replacement:
L (3.70 US qt) (3.08 Imp.qt)
8-1

SPECIFICATIONS
s: Tire air pressure (measured on cold
e type: tires):
uble cradle Loading condition:
r angle: 0–90 kg (0–198 lb)
00 ° Front:
225 kPa (33 psi) (2.25 kgf/cm2)
9.0 mm (4.69 in) Rear:
ire: 225 kPa (33 psi) (2.25 kgf/cm2) 2
Loading condition:
beless 90–215 kg (198–474 lb) (CAL)(ZAF)
90–216 kg (198–476 lb) (U49) 3
0/90-18M/C 61V Front:
acturer/model: 225 kPa (33 psi) (2.25 kgf/cm2)
IDGESTONE/G525 Rear: 4
acturer/model: 250 kPa (36 psi) (2.50 kgf/cm2)
NLOP/F20 Front wheel:
re: Wheel type: 5
Cast wheel
beless Rim size:
6
18M/C x MT2.15
0/90-15M/C 74V Rear wheel:
acturer/model: Wheel type: 7
IDGESTONE/G526 Cast wheel
acturer/model: Rim size:
NLOP/K525 15M/C x MT3.50 8
g: Front brake:
mum load: Type:
5 kg (474 lb) (CAL)(ZAF) Dual disc brake
9
6 kg (476 lb) (U49) Operation:
al weight of rider, passenger, cargo Right hand operation
accessories) Recommended fluid:
DOT 4
8-2

ght: Radiator fan fuse:
pe: 10.0 A
ogen bulb
oltage, wattage × quantity:
ght:
V, 60 W/55.0 W × 1
ake light:
V, 8.0 W/27.0 W × 2
urn signal/position light:
V, 23 W/8.0 W × 2
urn signal light:
V, 21.0 W × 2
ighting:
V, 3.0 W × 2
indicator light:
V, 3.0 W × 1
eam indicator light:
V, 3.0 W × 1
el warning light:
V, 3.0 W × 1
gnal indicator light:
V, 3.0 W × 1
vel warning light:
V, 3.0 W × 1
use:
A
ght fuse:
A
ng system fuse:
A
fuse:
A
8-3

CONSUMER INFORMATION
EAU26390 EAU26400
entification number Vehicle identification number
4
dentification number 1. Vehicle identification number
ey identification number is The vehicle identification number is 5

d into the key. Record this num- stamped into the steering head pipe.
he space provided and use it for Record this number in the space pro-
ce when ordering a new key. vided. 6
NOTE:
The vehicle identification number is 7
used to identify your motorcycle and
may be used to register your motorcy- 8
cle with the licensing authority in your
area.
9
9-1

9-2

EAU26550
could cause a crash or could cause injury or death, you should immediately
ministration (NHTSA) in addition to notifying Yamaha Motor Corporation,
ay open an investigation, and if it finds that a safety defect exists in a group
mpaign. However, NHTSA cannot become involved in individual problems
poration, U.S.A.
2
afety Hotline toll-free at 1-800-424-9393 (or 366-0123 in Washington, D.C.
nsportation, Washington, D.C. 20590. You can also obtain other information
3
9-3

EAU26560
PROHIBITED:
sing thereof: (1) The removal or rendering inoperative by any person other
cement of any device or element of design incorporated into any new ve-
e or delivery to the ultimate purchaser or while it is in use or (2) the use of
has been removed or rendered inoperative by any person.
TITUTE TAMPERING ARE THE ACTS LISTED BELOW”.
ystems; i.e., modification, removal, etc.
haust system
● Muffler
● Exhaust pipe
● Silencer
ake system
● Air cleaner case
● Air cleaner element
● Intake duct
9-4

EAU26632
purchased and installed on your vehicle will be required to document that

with the emissions warranty. The chart below is printed only as a reminder
table proof of maintenance work.
Servicing dealer
Mileage Remarks
name and address
2
9-5

Servicing dealer
Mileage Remarks
name and address
9-6

EAU26661
S.A. STREET AND ENDURO MOTORCYCLE LIMITED
9-7

9-8

EAU26750
.)
r warranty In addition, Travel and Recreation Interruption Protection
ce (Y.E.S.). (TRIP) is included at no extra cost. TRIP gives you up to
$150 reimbursement per occurrence for any reasonable
maha Motor
expenses you incur because your Yamaha needs
faction. You
covered service: replacement vehicle rental, emergency
e for extra
towing, phone calls, even food and lodging when you are 2
away from home. This superb coverage goes into effect
’s right for when you purchase Y.E.S., so it applies to any warranty
on certain repairs as well as covered repairs during your entire 3
y period. Y.E.S. plan period.
the same Y.E.S. coverage is honored at any authorized Yamaha
y – and it dealer nationwide.
4
efits. There
Y.E.S. coverage is transferable to a new owner if you
limited to
other plans.
sell or trade-in. That can make your Yamaha much more 5
valuable!
ust like the
ur Yamaha This excellent Y.E.S. plan coverage is only available to
ed factory-
6
Yamaha owners like you, and only while your Yamaha is still
within the Yamaha Limited Warranty period. So visit your
authorized Yamaha dealer to get all the facts. He can show
ed repairs. 7
you how easy it is to protect your investment with Yamaha
airs aren’t
Extended Service.
” expenses
8
9-9

benefits of
y knowing
after your
maha with
. We’ll be
d.
9-10

INDEX
O
ear oil............................................ 6-14 Oil level warning light ................................ 3-2
nd rear brake pads, checking....... 6-25 P
ork, adjusting................................. 3-10 Parking ...................................................... 5-5
ork, checking................................. 6-29 Part locations ............................................ 2-1
....................................................... 3-7 Pre-operation check list............................. 4-2
vel warning light.............................. 3-2 R
serve switch ................................... 3-4 Rear brake light switch, adjusting ........... 6-24
nk cap............................................. 3-6 Rear suspension, lubricating................... 6-29
replacing ...................................... 6-33 Rider seat.................................................. 3-9
S
bar switches ................................... 3-3 Safety defects, reporting ........................... 9-3
ght bulb, replacing......................... 6-34 Safety information ..................................... 1-1
holder .......................................... 3-10 Shifting ...................................................... 5-3
eam indicator light........................... 3-2 Shift pedal ................................................. 3-5
witch................................................ 3-4 Shock absorber assemblies, adjusting.... 3-12
Sidestand ................................................ 3-14
cation numbers ............................... 9-1 Spark plugs, checking ............................... 6-9
circuit cut-off system ................... 3-15 Specifications ............................................ 8-1
or and warning lights....................... 3-1 Speedometer unit...................................... 3-2
Starter (choke) lever.................................. 3-8
ntification number .......................... 9-1 Starting and warming up a cold engine..... 5-1
Start switch................................................ 3-4
location of ..................................... 1-5 Steering, checking................................... 6-30
Steering lock ............................................. 3-8
witch................................................ 3-1 Storage...................................................... 7-3
nance and lubrication, periodic....... 6-4 T
nance, emission control system ..... 6-3 Tachometer ............................................... 3-3
nance, periodic ............................... 6-1 Throttle cable free play, checking ........... 6-19
nance record................................... 9-5 Throttle grip and cable, checking and
abel ................................................ 9-2 lubricating ............................................. 6-27
Tires ........................................................ 6-20
indicator light................................. 3-1 Tool kit....................................................... 6-1
egulation ........................................ 9-4 Troubleshooting ...................................... 6-39

YAMAHA MOTOR CO., LTD.
PRINTED IN JAPAN
2005.5–0.1×1 !
(E)

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OWNER’S MANUAL

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in this manual by the following notations:

WARNING instructions could result in severe injury or death to the

key information to make procedures easier or clearer.

U AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY

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y before operating this vehicle.

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king) Indicator and warning lights

position to be turned to “P”. Turn signal indicator light “TURN” 7

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vel warning light “FUEL” Speedometer unit

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ant temperature gauge Handlebar switches

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witch “HORN” NOTE:

serve switch “FUEL”

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pedal Brake lever

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ove the fuel tank cap

2. Insert the key into the lock, and

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r (choke) lever Steering lock

r (choke) lever (page 3-8) 1. Steering lock

a cold engine requires a richer To lock the steering

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move the rider seat

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et holder Adjusting the front fork

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gn the bottom edge of the ad-

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on circuit cut-off system

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The neutral switch may be defective.

The sidestand switch may be defective.

The clutch switch may be defective.

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ibility. Vital components can start to deteriorate quickly and unexpectedly,

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ve Yamaha dealer bleed hydraulic system.

or wear. 6-24, 6-25

ve Yamaha dealer bleed hydraulic system.

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