OWNER’S MANUAL VMX12T(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.04-0.
U5GK15E0.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM INTRODUCTION EAU10080 Congratulations on your purchase of the Yamaha VMX12. 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.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM IMPORTANT MANUAL INFORMATION EAU10130 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.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM IMPORTANT MANUAL INFORMATION 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 RELIABILITY OF THIS MOTORCYCLE.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM IMPORTANT MANUAL INFORMATION EAU10192 AFFIX DEALER LABEL HERE VMX12T(C) OWNER’S MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in Japan.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM TABLE OF CONTENTS SAFETY INFORMATION ..................1-1 Location of important labels ...........1-5 DESCRIPTION ..................................2-1 Left view ..........................................2-1 Right view ........................................2-2 Controls and instruments ................2-3 INSTRUMENT AND CONTROL FUNCTIONS .......................................3-1 Main switch .....................................
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM TABLE OF CONTENTS Checking the wheel bearings .......6-30 Battery ..........................................6-30 Replacing the fuses ......................6-33 Replacing the headlight bulb ........6-34 Replacing a turn signal light bulb or the tail/brake light bulb ..........6-35 Front wheel ...................................6-36 Rear wheel ...................................6-37 Troubleshooting ............................6-39 Troubleshooting charts ..
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM SAFETY INFORMATION EAU10270 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: ● OBTAIN THOROUGH INSTRUCTIONS FROM A COMPETENT SOURCE ON ALL ASPECTS OF MOTORCYCLE OPERATION.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM SAFETY INFORMATION 1 ● ● turn due to EXCESSIVE SPEED or undercornering (insufficient lean angle for the speed). • Always obey the speed limit and never travel faster than warranted by road and traffic conditions. • Always signal before turning or changing lanes. Make sure that other motorists can see you. The posture of the operator and passenger is important for proper control.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM SAFETY INFORMATION Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 215 kg (474 lb) (CAL)(ZAF) / 216 kg (476 lb) (U49). When loading within this weight limit, keep the following in mind: ● Cargo and accessory weight should be kept as low and close to the motorcycle as possible.
U5GK15E0.book Page 4 Tuesday, April 13, 2004 3:52 PM SAFETY INFORMATION 1 Gasoline and exhaust gas ● GASOLINE IS HIGHLY FLAMMABLE: • Always turn the engine off when refueling. • Take care not to spill any gasoline on the engine or exhaust system when refueling. • Never refuel while smoking or in the vicinity of an open flame. ● Never start the engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time.
U5GK15E0.book Page 5 Tuesday, April 13, 2004 3:52 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
U5GK15E0.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM DESCRIPTION EAU10410 Left view 2 1. Clutch fluid reservoir (page 6-25) 2. Air filter element (page 6-18) 3. Fuse box (page 6-33) 4. Main fuse box (page 6-33) 5. Owner’s tool kit (page 6-1) 6. Shock absorber assembly spring preload adjusting ring (page 3-11) 7. Shock absorber assembly damping force adjusting knob (page 3-11) 8. Helmet holder (page 3-10) 9. Shift pedal (page 3-5) 10.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM DESCRIPTION EAU10420 Right view 2 1. Fuel tank cap (page 3-6) 2. Battery (page 6-30) 3. Coolant reservoir (page 6-14) 4. Front brake fluid reservoir (page 6-25) 5. Main switch (page 3-1) 6. Radiator cap (page 6-14) 7. Radiator (page 6-14) 8. Engine oil filter cartridge (page 6-11) 9. Engine oil level check window (page 6-11) 10.Brake pedal (page 3-6) 11.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch EAU10822 EAU11001 P (Parking) Indicator and warning lights 1. Push. 2. Turn. 1. 2. 3. 4. 5. 3 The main switch controls the ignition and lighting systems. The various main switch positions are described below. EAU10510 ON All electrical systems are supplied with power, and the headlight, meter lighting, taillight and position lights come on, and the engine can be started.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11090 EAU32320 High beam indicator light “HIGH BEAM” This indicator light comes on when the high beam of the headlight is switched on. Fuel level warning light “FUEL” This warning light comes on when the fuel level drops below approximately 3.0 L (0.79 US gal) (0.66 Imp.gal). When this occurs, set the fuel reserve switch to the “RES” position and refuel as soon as possible.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11851 Tachometer EAU12171 Coolant temperature gauge EAU12343 Handlebar switches Left 3 1. Tachometer 2. Tachometer red zone 1. Coolant temperature gauge 2. Coolant temperature gauge red zone The electric tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. With the key in the “ON” position, the coolant temperature gauge indicates the temperature of the coolant.
U5GK15E0.book Page 4 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12410 Dimmer switch “LIGHTS” Set the switch to “HI” for the high beam and to “LO” for the low beam. EAU12510 Horn switch “HORN” Press this switch to sound the horn. EAU12650 EAU12420 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 center position.
U5GK15E0.book Page 5 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12820 EAU12870 EAU12890 Clutch lever Shift pedal Brake lever 1. Clutch lever 1. Shift pedal 1. Brake lever The clutch lever is located at the left handlebar grip. To disengage the clutch, pull the lever toward the handlebar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation.
U5GK15E0.book Page 6 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13060 Fuel tank cap To remove the fuel tank cap 1. Brake pedal The brake pedal is on the right side of the motorcycle. To apply the rear brake, press down on the brake pedal. 1. Opening lever 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.
U5GK15E0.book Page 7 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13210 Fuel ECA10070 CAUTION: Immediately wipe off spilled fuel with a clean, dry, soft cloth, since fuel may deteriorate painted surfaces or plastic parts. EAU13300 3 1. Fuel tank filler tube 2. Fuel level Make sure that there is sufficient fuel in the tank. Fill the fuel tank to the bottom of the filler tube as shown.
U5GK15E0.book Page 8 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13630 Starter (choke) lever 1. 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). EAU13730 Steering lock 1. Steering lock To lock the steering 1. Turn the handlebar all the way to the right. 2.
U5GK15E0.book Page 9 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS 2. Place the rider seat in the original position, and then tighten the bolts and screws. EAU14230 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. NOTE: Make sure that the seat is properly secured before riding. 3. Return the rider seat backrest to the original position. 3 1. Bolt 2.
U5GK15E0.book Page 10 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14281 Helmet holder EAU14660 Adjusting the front fork This front fork is equipped with air valves for adjusting the spring rate. EWA10180 WARNING Always adjust both fork legs equally, 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. 1. Helmet holder 2. Unlock.
U5GK15E0.book Page 11 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS 3 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, decrease the air pressure by pushing each valve stem down. Spring rate: Minimum/standard (soft): Air pressure = 40 kPa (5.7 psi) (0.4 kgf/cm²) Maximum (hard): Air pressure = 100 kPa (14 psi) (1.
U5GK15E0.book Page 12 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS NOTE: ● Align the bottom edge of the adjusting ring with the appropriate setting on the shock absorber. ● Use the special wrench included in the owner’s tool kit to make this adjustment. Spring preload: Minimum (soft): 1 Standard: 1 Maximum (hard): 5 Damping force To increase the damping force and thereby harden the damping, turn the adjusting knob on each shock absorber assembly in direction (a).
U5GK15E0.book Page 13 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15270 V-Boost ECA10180 EAU15300 CAUTION: Sidestand If the V-Boost does not operate, ask a Yamaha dealer to inspect it. The sidestand is located on the left side of the frame. Raise the sidestand or lower it with your foot while holding the vehicle upright. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations.
U5GK15E0.book Page 14 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer repair it if it does not function properly. EAU15321 Ignition circuit cut-off system The ignition circuit cut-off system (comprising the sidestand switch, clutch switch and neutral switch) has the following functions. ● It prevents starting when the transmission is in gear and the sidestand is up, but the clutch lever is not pulled.
U5GK15E0.book Page 15 Tuesday, April 13, 2004 3:52 PM INSTRUMENT AND CONTROL FUNCTIONS With the engine turned off: 1. Move the sidestand down. 2. Make sure that the engine stop switch is turned on. 3. Turn the key on. 4. Shift the transmission into the neutral position. 5. Push the start switch. Does the engine start? NOTE: This check is most reliable if performed with a warmed-up engine. 3 YES NO The neutral switch may be defective.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM PRE-OPERATION CHECKS EAU15591 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.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM PRE-OPERATION CHECKS EAU15602 Pre-operation check list ITEM 4 CHECKS PAGE Fuel • Check fuel level in fuel tank. • Refuel if necessary. • Check fuel line for leakage. 3-7 Engine oil • Check oil level in engine. • If necessary, add recommended oil to specified level. • Check vehicle for oil leakage. 6-11 Final gear oil • Check vehicle for oil leakage. 6-13 Coolant • Check coolant level in reservoir.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM PRE-OPERATION CHECKS ITEM CHECKS 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. PAGE Clutch • • • • • Throttle grip • Make sure that operation is smooth. • Check cable free play. • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● 5 ● Become thoroughly familiar with all operating controls and their functions before riding. Consult a Yamaha dealer regarding any control or function that you do not thoroughly understand. Never start the engine or operate it in a closed area for any length of time. Exhaust fumes are poisonous, and inhaling them can cause loss of consciousness and death within a short time.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM OPERATION AND IMPORTANT RIDING POINTS ● ● is pushed, and they should go off when the start switch is released. If the oil level warning light flickers or remains on after starting, immediately stop the engine, and then check the engine oil level and the vehicle for oil leakage. If necessary, add engine oil, and then check the warning light again.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM OPERATION AND IMPORTANT RIDING POINTS EAU16640 Starting a warm engine EAU16671 Shifting ECA10260 CAUTION: Follow the same procedure as for starting a cold engine with the exception that the starter (choke) is not required when the engine is warm. ● 1. Shift pedal 5 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 illustration.
U5GK15E0.book Page 4 Tuesday, April 13, 2004 3:52 PM OPERATION AND IMPORTANT RIDING POINTS 4. At the recommended shift points shown in the following table, 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 position.) 6. Open the throttle part way and gradually release the clutch lever. 7. Follow the same procedure when shifting to the next higher gear.
U5GK15E0.book Page 5 Tuesday, April 13, 2004 3:52 PM OPERATION AND IMPORTANT RIDING POINTS ECA10331 EAU17200 CAUTION: Parking After 1000 km (600 mi) of operation, the engine oil and final gear oil must be changed, and the oil filter cartridge or element replaced. When parking, stop the engine, and then remove the key from the main switch. 1600 km (1000 mi) and beyond The vehicle can now be operated normally.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17231 EAU17301 PERIODIC MAINTENANCE Safety is an obligation of the owner. Periodic inspection, adjustment and lubrication will keep your vehicle in the safest and most efficient condition possible. The most important points of motorcycle inspection, adjustment, and lubrication are explained on the following pages.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR you in the performance of preventive maintenance and minor repairs. However, 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 experience required for a particular job, have a Yamaha dealer perform it for you.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. ITEM ROUTINE 1 * Fuel line • Check fuel hoses for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace. 3 Spark plugs • Check condition. • Adjust gap and clean. • Replace every 8000 mi (13000 km) or 12 months. 4 * Valve clearance • Check and adjust valve clearance when engine is cold.
U5GK15E0.book Page 4 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32182 General maintenance and lubrication chart INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 1 * Air filter element • Clean with compressed air. • Replace if necessary.
U5GK15E0.book Page 5 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE 600 mi (1000 km) or 1 month ODOMETER READINGS 4000 mi (7000 km) or 6 months 8000 mi 12000 mi 16000 mi 20000 mi (13000 km) (19000 km) (25000 km) (31000 km) or or or or 12 months 18 months 24 months 30 months 9 * Wheel bearings • Check bearings for smooth operation. • Replace if necessary. 10 * Swingarm pivot bearings • Check bearing assemblies for looseness.
U5GK15E0.book Page 6 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL ITEM 18 * Shock absorber assemblies • Check operation and for oil leakage. • Replace if necessary. 19 Engine oil • Change (warm engine before draining). √ 20 * Engine oil filter cartridge • Replace. √ 21 * Cooling system ROUTINE 600 mi (1000 km) or 1 month No. • Check hoses for cracks or damage. • Replace if necessary.
U5GK15E0.book Page 7 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. EAU17660 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.
U5GK15E0.book Page 8 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 2. Push down on the rear of the cowling until it locks in place. 3. Remove the key from the lock. EAU18721 Removing and installing the cowling and panels The cowling and panels shown 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. EAU19180 Panel A 1. Unlock. 2.
U5GK15E0.book Page 9 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19210 Panel B To remove the panel Remove the screws, and then take the panel off. EAU19543 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 maintenance and lubrication chart.
U5GK15E0.book Page 10 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Check each spark plug for electrode erosion and excessive carbon or other deposits, and replace it if necessary. Specified spark plug: NGK/DPR8EA-9 DENSO/X24EPR-U9 To install a spark plug 1. Measure the spark plug gap with a wire thickness gauge and, if necessary, adjust the gap to specification. 6 2.
U5GK15E0.book Page 11 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19871 Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter cartridge replaced at the intervals specified in the periodic maintenance and lubrication chart. NOTE: The engine oil should be between the minimum and maximum level marks. 2. Place an oil pan under the engine to collect the used oil. 3.
U5GK15E0.book Page 12 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Skip steps 4–6 if the oil filter cartridge is not being replaced. 4. Remove the oil filter cartridge with an oil filter wrench. 1. O-ring 1. Torque wrench NOTE: Make sure that the O-ring is properly seated. 6 1. Oil filter cartridge 2. Oil filter wrench NOTE: An oil filter wrench is available at a Yamaha dealer. 6.
U5GK15E0.book Page 13 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20000 Recommended engine oil: See page 8-1. Oil quantity: Without oil filter cartridge replacement: 3.50 L (3.70 US qt) (3.08 Imp.qt) With oil filter cartridge replacement: 3.80 L (4.02 US qt) (3.34 Imp.qt) ECA11620 CAUTION: ● ● In order to prevent clutch slippage (since the engine oil also lubricates the clutch), do not mix any chemical additives.
U5GK15E0.book Page 14 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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. 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. Tightening torque: Final gear oil drain bolt: 23 Nm (2.3 m·kgf, 17 ft·lbf) 4.
U5GK15E0.book Page 15 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10470 NOTE: The coolant should be between the minimum and maximum level marks. CAUTION: ● ● 1. Maximum level mark 2. Minimum level mark 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. Coolant reservoir capacity (up to the maximum level mark): 0.30 L (0.32 US qt) (0.
U5GK15E0.book Page 16 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 1. Radiator cap 5. Turn the coolant drain cock, making sure to align the “ON” with the position indicator. 1. Water pump drain bolt 7. Remove the cylinder drain plug covers on the outside of the cylinder blocks by removing the screws. 6 1. Rubber coolant drain plug 9. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water. 10.
U5GK15E0.book Page 17 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10470 NOTE: Check the rubber plugs for damage and replace them if necessary. 12. Turn the coolant drain cock, making sure to align the “OFF” with the position indicator. 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.
U5GK15E0.book Page 18 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● EAU20510 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 frequently if you are riding in unusually wet or dusty areas. 1. Remove cowling A. (See page 6-8.) 2. Remove the air filter case cover by removing the screws. 6 6.
U5GK15E0.book Page 19 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment. Therefore, all carburetor adjustments should be left to a Yamaha dealer, who has the necessary professional knowledge and experience.
U5GK15E0.book Page 20 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32380 Tires To maximize the performance, durability, and safe operation of your motorcycle, 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. EWA10500 WARNING ● 6 ● The tire air pressure must be checked and adjusted on cold tires (i.e.
U5GK15E0.book Page 21 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR if the tire has a nail or glass fragments in it, or if the sidewall is cracked, contact a Yamaha dealer immediately and have the tire replaced. Minimum tire tread depth (front and rear): 1.0 mm (0.04 in) EWA10580 WARNING ● ● It is dangerous to ride with a worn-out tire. When a tire tread begins to show crosswise lines, have a Yamaha dealer replace the tire immediately.
U5GK15E0.book Page 22 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21980 Cast wheels 6 To maximize the performance, durability, and safe operation of your motorcycle, 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.
U5GK15E0.book Page 23 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR any consequences caused by the use of items which have not been approved by Yamaha. EAU22071 Clutch lever free play Since this model is equipped with a hydraulic clutch, adjusting the clutch lever free play is not needed. However, it is necessary to check the clutch fluid level and check the hydraulic system for leakage before each ride.
U5GK15E0.book Page 24 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10630 WARNING ● ● 6 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 hydraulic system, have a Yamaha dealer bleed the system before operating the motorcycle.
U5GK15E0.book Page 25 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22680 Checking the brake and clutch fluid levels ● Clutch ● Front brake 1. Minimum level mark 1. Minimum level mark Rear brake 1. Panel B 2. Minimum level mark Insufficient brake fluid may allow air to enter the brake or clutch systems, possibly causing them to become ineffective. Before riding, check that the brake fluid is above the minimum level mark and replenish if necessary.
U5GK15E0.book Page 26 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 6 significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may deteriorate painted surfaces or plastic parts. Always clean up spilled fluid immediately. As the brake pads wear, it is normal for the brake fluid level to gradually go down. However, if the brake fluid level goes down suddenly, have a Yamaha dealer check the cause.
U5GK15E0.book Page 27 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23110 Checking and lubricating the throttle grip and cable EAU23131 Checking and lubricating the brake and shift pedals Recommended lubricant: Lithium-soap-based grease (all-purpose grease) The operation of the throttle grip should be checked before each ride. In addition, the cable should be lubricated or replaced at the intervals specified in the periodic maintenance chart.
U5GK15E0.book Page 28 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Checking and lubricating the brake and clutch levers EAU23210 Checking and lubricating the centerstand and sidestand EAU23250 Lubricating the rear suspension The pivoting points of the rear suspension must be lubricated at the intervals specified in the periodic maintenance and lubrication chart.
U5GK15E0.book Page 29 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23271 EAU23280 Checking the front fork Checking the steering The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart. 1.
U5GK15E0.book Page 30 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23290 Checking the wheel bearings EAU23351 Battery The front and rear wheel bearings must be checked at the intervals specified in the periodic maintenance and lubrication 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. 1. Battery 2. Battery breather hose 3. Pass through the cable guide.
U5GK15E0.book Page 31 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that the vehicle is positioned straight up when checking the electrolyte level. 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. 2. Check the electrolyte level in the battery. NOTE: The electrolyte should be between the minimum and maximum level marks. 1. Ignition coil assembly 2. Bolt 3.
U5GK15E0.book Page 32 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● 6 • INTERNAL: Drink large quantities of water or milk and immediately call a physician. • EYES: Flush with water for 15 minutes and seek prompt medical attention. Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space. KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN.
U5GK15E0.book Page 33 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. After installation, make sure that the battery leads are properly connected to the battery terminals and that the breather hose is properly routed, in good condition, and not obstructed. EAU23570 Replacing the fuses The main fuse box is located under the rider seat. (See page 3-9.
U5GK15E0.book Page 34 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23780 Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Radiator fan fuse: 10.0 A Ignition fuse: 10.0 A Replacing the headlight bulb This model is equipped with a quartz bulb headlight. If the headlight bulb burns out, replace it as follows. 1. Remove the headlight unit by removing the screws. 1. Headlight bulb holder ECA10640 3.
U5GK15E0.book Page 35 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10790 WARNING Headlight bulbs get very hot. Therefore, keep flammable products away from a lit headlight bulb, and do not touch the bulb until it has cooled down. EAU24281 Replacing a turn signal light bulb or the tail/brake light bulb 1. Remove the lens by removing the screws. 4. Place a new headlight bulb into position, and then secure it with the bulb holder. 1. Turn signal light bulb ECA10660 2.
U5GK15E0.book Page 36 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel EAU24430 To remove the front wheel EWA10820 WARNING ● ● 6 It is advisable to have a Yamaha dealer service the wheel. Securely support the motorcycle so that there is no danger of it falling over. 1. Place the motorcycle on the centerstand. 2. Disconnect the speedometer cable from the front wheel. 3. Remove the brake calipers by removing the bolts.
U5GK15E0.book Page 37 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 4. Install the brake calipers by installing the bolts. NOTE: Make sure that there is enough space between the brake pads before installing the brake calipers onto the brake discs. 5. Take the motorcycle off the centerstand so that the front wheel is on the ground. 6. Tighten the wheel axle, then the front wheel axle pinch bolt and the brake caliper bolts to the specified torques.
U5GK15E0.book Page 38 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 7. Pull the wheel to the right to separate it from the final gear case, and then remove it. ECA11180 CAUTION: Do not push the brake pedal after the wheel has been removed together with the brake disc, otherwise the brake pads will be forced shut. 1. 2. 3. 4. 5. 6. 6 Nut Cotter pin Brake torque rod Bolt Spacer Brake caliper bracket 5. While supporting the rear wheel, pull the wheel axle out. 6.
U5GK15E0.book Page 39 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR 8. Install the brake torque rod cotter pin. EWA10830 WARNING Always use a new cotter pin. EAU25870 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may occur during operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power.
U5GK15E0.book Page 40 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU25941 Troubleshooting charts Starting problems or poor engine performance EWA10840 WARNING Keep away open flames and do not smoke while checking or working on the fuel system. 1. Fuel There is enough fuel. Check the compression. There is no fuel. Supply fuel. Check the fuel level in the fuel tank. The engine does not start. Check the compressoin. 2. Compression 6 There is compression.
U5GK15E0.book Page 41 Tuesday, April 13, 2004 3:52 PM PERIODIC MAINTENANCE AND MINOR REPAIR Engine overheating EWA10400 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.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM MOTORCYCLE CARE AND STORAGE ucts onto seals, gaskets and wheel axles. Always rinse the dirt and degreaser off with water. EAU26060 Care While the open design of a motorcycle reveals the attractiveness of the technology, it also makes it more vulnerable. Rust and corrosion can develop even if high-quality components are used. A rusty exhaust pipe may go unnoticed on a car, however, it detracts from the overall appearance of a motorcycle.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM MOTORCYCLE CARE AND STORAGE 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.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM MOTORCYCLE CARE AND STORAGE ● Avoid using abrasive polishing compounds as they will wear away the paint. NOTE: Consult a Yamaha dealer for advice on what products to use. EAU26230 Storage Short-term Always store your motorcycle in a cool, dry place and, if necessary, protect it against dust with a porous cover.
U5GK15E0.book Page 4 Tuesday, April 13, 2004 3:52 PM MOTORCYCLE CARE AND STORAGE EWA10950 WARNING To prevent damage or injury from sparking, make sure to ground the spark plug electrodes while turning the engine over. °C (90 °F)]. For more information on storing the battery, see page 6-30. NOTE: Make any necessary repairs before storing the motorcycle. 6. Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand/centerstand. 7.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM SPECIFICATIONS Dimensions: Overall length: 2300 mm (90.6 in) Overall width: 795 mm (31.3 in) Overall height: 1160 mm (45.7 in) Seat height: 765 mm (30.1 in) Wheelbase: 1590 mm (62.6 in) Ground clearance: 145 mm (5.71 in) Minimum turning radius: 2900 mm (114.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM SPECIFICATIONS Manufacturer/model: DENSO/X24EPR-U9 Spark plug gap: 0.8–0.9 mm (0.031–0.035 in) Clutch: Clutch type: Wet, multiple-disc Transmission: Primary reduction system: Spur gear Primary reduction ratio: 87/49 (1.776) Secondary reduction system: Shaft drive Secondary reduction ratio: 21/27 × 33/09 (2.852) Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 43/17 (2.529) 2nd: 39/22 (1.773) 3rd: 31/23 (1.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM SPECIFICATIONS Front suspension: Type: Telescopic fork Spring/shock absorber type: Coil-air spring/oil damper Wheel travel: 140.0 mm (5.51 in) Rear suspension: Type: Swingarm Spring/shock absorber type: Coil spring/oil damper Wheel travel: 100.0 mm (3.94 in) Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: A.C. magneto Battery: 8 Model: YB16AL-A2 Voltage, capacity: 12 V, 16.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM CONSUMER INFORMATION EAU26351 Identification numbers EAU26390 EAU26400 Key identification number Vehicle identification number 1. Key identification number 1. Vehicle identification number The key identification number is stamped into the key. Record this number in the space provided and use it for reference when ordering a new key. The vehicle identification number is stamped into the steering head pipe.
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM CONSUMER INFORMATION EAU26530 Model label 1. Model label The model label is affixed under cowling A. (See page 6-8.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
U5GK15E0.book Page 3 Tuesday, April 13, 2004 3:52 PM CONSUMER INFORMATION EAU26550 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 immediately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A.
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U5GK15E0.book Page 5 Tuesday, April 13, 2004 3:52 PM CONSUMER INFORMATION EAU26631 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.
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U5GK15E0.book Page 7 Tuesday, April 13, 2004 3:52 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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U5GK15E0.book Page 9 Tuesday, April 13, 2004 3:52 PM CONSUMER INFORMATION EAU26750 YAMAHA EXTENDED SERVICE (Y.E.S.) Keep your Yamaha protected even after your warranty expires with genuine Yamaha Extended Service (Y.E.S.). In addition, Travel and Recreation Interruption Protection (TRIP) is included at no extra cost.
U5GK15E0.book Page 10 Tuesday, April 13, 2004 3:52 PM CONSUMER INFORMATION We urge you to act now. You’ll get the excellent benefits of TRIP coverage right away, and you’ll rest easy knowing you’ll have strong factory-backed protection even after your Yamaha Limited Warranty expires. A special note: If visiting your dealer isn’t convenient, contact Yamaha with your Primary ID number (your frame number). We’ll be happy to help you get the Y.E.S. coverage you need. Yamaha Service Marketing P.O.
U5GK15E0.book Page 1 Tuesday, April 13, 2004 3:52 PM INDEX A Accessories and replacement parts ..... 6-22 Air filter element, cleaning .................... 6-18 H D Dimmer switch ........................................ 3-4 E Engine break-in ...................................... 5-4 Engine oil and oil filter cartridge ........... 6-11 Engine, starting a warm.......................... 5-3 Oil level warning light .............................. 3-2 P Parking..............................................
U5GK15E0.book Page 2 Tuesday, April 13, 2004 3:52 PM INDEX Tires ...................................................... 6-20 Tool kit .................................................... 6-1 Troubleshooting .................................... 6-39 Troubleshooting charts ......................... 6-40 Turn signal indicator light ........................ 3-1 Turn signal light bulb or tail/brake light bulb, replacing ............. 6-35 Turn signal switch ...................................
OWNER’S MANUAL VMX12T(C) YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2004.04-0.
