OWNER’S MANUAL VMX12S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.04-0.
5GK14.
5GK14.book Page 1 Friday, April 11, 2003 1:07 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.
5GK14.book Page 1 Friday, April 11, 2003 1:07 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.
GK14.book Page 2 Friday, April 11, 2003 1:07 PM IMPORTANT MANUAL INFORMATION EAU10191 AFFIX DEALER LABEL HERE VMX12S OWNER’S MANUAL ©2003 by Yamaha Motor Corporation, U.S.A. 1st edition, April 2003 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.
5GK14.book Page 1 Friday, April 11, 2003 1:07 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 .....................................
5GK14.book Page 2 Friday, April 11, 2003 1:07 PM TABLE OF CONTENTS Checking the front fork .................6-29 Checking the steering ...................6-30 Checking the wheel bearings .......6-30 Battery ..........................................6-31 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 ..........................
5GK14.book Page 1 Friday, April 11, 2003 1:07 PM SAFETY INFORMATION EAU10270 1 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.
5GK14.book Page 2 Friday, April 11, 2003 1:07 PM SAFETY INFORMATION ● ● 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.
5GK14.book Page 3 Friday, April 11, 2003 1:07 PM SAFETY INFORMATION 1 Loading The total weight of the operator, passenger, accessories and cargo must not exceed the maximum load limit of 216.0 kg (476 lb). 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. Make sure to distribute the weight as evenly as possible on both sides of the motorcycle to minimize imbalance or instability.
5GK14.book Page 4 Friday, April 11, 2003 1:07 PM SAFETY INFORMATION 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.
5GK14.book Page 5 Friday, April 11, 2003 1:07 PM SAFETY INFORMATION EAU10381 Location of important labels Please read the following important labels carefully before operating this vehicle.
5GK14.
5GK14.book Page 1 Friday, April 11, 2003 1:07 PM DESCRIPTION EAU10410 Left view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Shift pedal (page 3-5) 10.
5GK14.book Page 2 Friday, April 11, 2003 1:07 PM DESCRIPTION EAU10420 Right view 2 1. 2. 3. 4. 5. 6. 7. 8. 9. Engine oil level check window (page 6-10) 10.Brake pedal (page 3-6) 11.
5GK14.book Page 3 Friday, April 11, 2003 1:07 PM DESCRIPTION EAU10430 Controls and instruments 2 1. 2. 3. 4. 5. 6. 7. 8.
5GK14.book Page 1 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS EAU10450 Main switch EAU10821 EAU11000 Indicator and warning lights P (Parking) 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. The key cannot be removed.
5GK14.book Page 2 Friday, April 11, 2003 1:07 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.
5GK14.book Page 3 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS EAU11851 Tachometer EAU12171 Coolant temperature gauge EAU12341 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.
5GK14.book Page 4 Friday, April 11, 2003 1:07 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 3 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.
5GK14.book Page 5 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12820 Clutch lever EAU12870 Shift pedal EAU12890 Brake lever 3 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.
5GK14.book Page 6 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS EAU12941 Brake pedal EAU13060 Fuel tank cap To remove the fuel tank cap 3 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.
5GK14.book Page 7 Friday, April 11, 2003 1:07 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 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.
5GK14.book Page 8 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS EAU13630 EAU13730 Starter (choke) lever Steering lock 1. Starter (choke) lever 1. Steering lock 3 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). To lock the steering 1. Turn the handlebar all the way to the right. 2.
5GK14.book Page 9 Friday, April 11, 2003 1:07 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. 1. Bolt 2.
5GK14.book Page 10 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS EAU14280 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. 3 Adjust the spring rate as follows. 1. Elevate the front wheel by placing the vehicle on the centerstand. 1. Helmet holder 2. Unlock.
5GK14.book Page 11 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS 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 (0.4 kgf/cm², 5.7 psi) Maximum (hard): Air pressure = 100 kPa (1.
5GK14.book Page 12 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS Spring preload: Minimum (soft): 1 Standard: 1 Maximum (hard): 5 Damping force: Minimum (soft): 1 Standard: 1 Maximum (hard): 4 EWA10230 3 Damping force WARNING 1. Damping force adjusting knob 2. Position indicator To increase the damping force and thereby harden the damping, turn the adjusting knob on each shock absorber assembly in direction (a).
5GK14.book Page 13 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS ● Always have a Yamaha dealer service the shock absorbers. EAU15270 V-Boost ECA10180 CAUTION: If the V-Boost does not operate, ask a Yamaha dealer to inspect it. 3 The V-Boost is a vital part of the engine and requires very sophisticated adjustment. Adjustment should be left to a Yamaha dealer who has the professional knowledge and experience to do so.
5GK14.book Page 14 Friday, April 11, 2003 1:07 PM INSTRUMENT AND CONTROL FUNCTIONS EAU15300 Sidestand 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. 3 below and have a Yamaha dealer repair it if it does not function properly. NOTE: The built-in sidestand switch is part of the ignition circuit cut-off system, which cuts the ignition in certain situations.
5GK14.book Page 15 Friday, April 11, 2003 1:07 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? YES NOTE: This check is most reliable if performed with a warmed-up engine. NO The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer.
5GK14.book Page 1 Friday, April 11, 2003 1:07 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. Therefore, it is very important, in addition to a thorough visual inspection, to check the following points before each ride.
5GK14.book Page 2 Friday, April 11, 2003 1:07 PM PRE-OPERATION CHECKS EAU15601 Pre-operation check list ITEM 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. 6-10 Final gear oil • Check vehicle for oil leakage. 6-13 Coolant • Check coolant level in reservoir.
5GK14.book Page 3 Friday, April 11, 2003 1:07 PM PRE-OPERATION CHECKS ITEM 4 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.
5GK14.book Page 1 Friday, April 11, 2003 1:07 PM OPERATION AND IMPORTANT RIDING POINTS EAU15950 EWA10270 WARNING ● ● ● 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.
5GK14.book Page 2 Friday, April 11, 2003 1:07 PM OPERATION AND IMPORTANT RIDING POINTS ● 5 ● 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.
5GK14.book Page 3 Friday, April 11, 2003 1:07 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 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.
5GK14.book Page 4 Friday, April 11, 2003 1:07 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.
5GK14.book Page 5 Friday, April 11, 2003 1:07 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.
5GK14.book Page 1 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17230 EAU17300 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.
5GK14.book Page 2 Friday, April 11, 2003 1:07 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.
5GK14.book Page 3 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU17600 Periodic maintenance chart for the emission control system INITIAL No. 6 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 * Fuel line • Check fuel hose for cracks or damage. • Replace if necessary. 2 * Fuel filter • Replace.
5GK14.book Page 4 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU32181 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. (See NOTE.) • Replace if necessary.
5GK14.book Page 5 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. ITEM ROUTINE ODOMETER READINGS 600 mi (1000 km) or 1 month 4000 mi (7000 km) or 6 months √ √ √ √ Repack. √ 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 8 * Steering bearings • Check bearing assembly for looseness. • Moderately repack with lithiumsoap-based grease every 16000 mi (25000 km) or 24 months.
5GK14.book Page 6 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR INITIAL No. 17 * ITEM Cooling system ROUTINE 600 mi (1000 km) or 1 month • Check hoses for cracks or damage. • Replace if necessary. 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 √ √ • Change with ethylene glycol antifreeze coolant every 24 months.
5GK14.book Page 7 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR • Replace the oil seals on the inner parts of the brake or clutch master cylinders, caliper cylinders and clutch release cylinder every two years. • Replace the brake and clutch hoses every four years or if cracked or damaged.
5GK14.book Page 8 Friday, April 11, 2003 1:07 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. EAU18720 Removing and installing the cowling and panels EAU19180 Panel A 1. Unlock. 2. Pull the cowling off as shown. 1. Cowling A 2. Panel A 3. Panel B The cowling and panels shown above need to be removed to perform some of the maintenance jobs described in this chapter.
5GK14.book Page 9 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU19210 Panel B To remove the panel Remove the screws, and then take the panel off. EAU19542 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.
5GK14.book Page 10 Friday, April 11, 2003 1:07 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 or 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. 2.
5GK14.book Page 11 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: The engine oil should be between the minimum and maximum level marks. 6 1. Engine oil level check window 2. Maximum level mark 3. Minimum level mark 2. Place an oil pan under the engine to collect the used oil. 3. Remove the engine oil filler cap and drain bolt to drain the oil from the crankcase. 4. Remove the oil filter cartridge with an oil filter wrench. 1. Engine oil filler cap 1. Oil filter cartridge 2.
5GK14.book Page 12 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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 1. O-ring NOTE: Make sure that the O-ring is properly seated. 6. Install the new oil filter cartridge with an oil filter wrench, and then tighten it to the specified torque with a torque wrench. CAUTION: 1.
5GK14.book Page 13 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU20000 NOTE: After the engine is started, the engine oil level warning light should go off if the oil level is sufficient. ECA10400 CAUTION: If the oil level warning light flickers or remains on, immediately turn the engine off and have a Yamaha dealer check the vehicle. 10. Turn the engine off, and then check the oil level and correct it if necessary.
5GK14.book Page 14 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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. Add the recommended final gear oil to the brim of the filler hole.
5GK14.book Page 15 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10470 CAUTION: ● ● 6 ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion.
5GK14.book Page 16 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Check the rubber plugs for damage and replace them if necessary. 1. Water pump drain bolt 7. Remove the cylinder drain plug covers on the outside of the cylinder blocks by removing the screws. 1. Rubber coolant drain plug 9. After the coolant is completely drained, thoroughly flush the cooling system with clean tap water. 10. Install the water pump drain bolt, and then tighten it to the specified torque.
5GK14.book Page 17 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR ECA10470 CAUTION: ● ● 6 ● If coolant is not available, use distilled water or soft tap water instead. Do not use hard water or salt water since it is harmful to the engine. If water has been used instead of coolant, replace it with coolant as soon as possible, otherwise the engine may not be sufficiently cooled and the cooling system will not be protected against frost and corrosion.
5GK14.book Page 18 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● The engine should never be operated without the air filter element installed, otherwise the piston(s) and/or cylinder(s) may become excessively worn. 6. Install the air filter case cover by installing the screws. 7. Install the cowling. EAU21270 Adjusting the carburetors The carburetors are important parts of the engine and emission control system, which require very sophisticated adjustment.
5GK14.book Page 19 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU21380 Adjusting the throttle cable free play EAU21400 EAU32380 Adjusting the valve clearance Tires The valve clearance changes with use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
5GK14.book Page 20 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR Tire air pressure (measured on cold tires): 0.0–90.0 kg (0–198 lb): Front: 225 kPa (33 psi) (2.25 kgf/cm²) Rear: 225 kPa (33 psi) (2.25 kgf/cm²) 90.0–216.0 kg (198–476 lb): Front: 225 kPa (33 psi) (2.25 kgf/cm²) Rear: 250 kPa (36 psi) (2.50 kgf/cm²) Maximum load*: 216.0 kg (476 lb) * Total weight of rider, passenger, cargo and accessories LOAD YOUR VEHICLE.
5GK14.book Page 21 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EWA10460 WARNING ● ● 6 The front and rear tires should be of the same make and design, otherwise the handling characteristics of the vehicle cannot be guaranteed. After extensive tests, only the tires listed below have been approved for this model by Yamaha Motor Co., Ltd.
5GK14.book Page 22 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22010 Tightening torques: Valve stem nut: 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf) Valve stem locknut: 1.6 Nm (0.16 m·kgf, 1.2 ft·lbf) Accessories and replacement parts any consequences caused by the use of items which have not been approved by Yamaha. EWA10620 WARNING This motorcycle is not designed to pull a trailer or to be attached to a sidecar.
5GK14.book Page 23 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22070 Clutch lever free play 6 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.
5GK14.book Page 24 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22240 Adjusting the brake pedal position the braking performance, which may result in loss of control and an accident. 1. Distance between brake pedal and footrest EAU22270 Adjusting the rear brake light switch 1. Rear brake light switch 2. Rear brake light switch adjusting nut The top of the brake pedal should be positioned approximately 20.0 mm (0.79 in) below the top of the footrest as shown.
5GK14.book Page 25 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU22311 Checking the front and rear brake pads EAU22680 Checking the brake and clutch fluid levels Clutch Front brake 1. Minimum level mark 1. Brake pad wear indicator 6 The front and rear brake pads must be checked for wear at the intervals specified in the periodic maintenance and lubrication chart.
5GK14.book Page 26 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● ● When checking the fluid level, make sure that the top of the brake or clutch fluid reservoir is level. Use only the recommended quality brake fluid, otherwise the rubber seals may deteriorate, causing leakage and poor braking or clutch performance. Recommended brake and clutch fluid: DOT 4 brake fluid ● ● ● Refill with the same type of brake fluid.
5GK14.book Page 27 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23090 EAU23110 Checking and lubricating the cables Checking and lubricating the throttle grip and cable The operation of all control cables and the condition of the cables should be checked before each ride, and the cables and cable ends should be lubricated if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer check or replace it.
5GK14.book Page 28 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23140 Recommended lubricant: Lithium-soap-based grease (all-purpose grease) EAU23210 Checking and lubricating the brake and clutch levers Checking and lubricating the centerstand and sidestand The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lubricated if necessary.
5GK14.book Page 29 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR 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. EAU23270 Checking the front fork The condition and operation of the front fork must be checked as follows at the intervals specified in the periodic maintenance and lubrication chart.
5GK14.book Page 30 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23280 EAU23290 Checking the steering Checking the wheel bearings 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. Place a stand under the engine to raise the front wheel off the ground.
5GK14.book Page 31 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23351 Battery 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. Battery 2.
5GK14.book Page 32 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR ● 1. Ignition coil assembly 2. Bolt 3. Coupler 9. Add distilled water to raise the electrolyte to the maximum level mark. EWA10760 WARNING ● Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns. Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries. In case of contact, administer the following FIRST AID.
5GK14.book Page 33 Friday, April 11, 2003 1:07 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.) ECA10600 CAUTION: 1. Positive battery lead (red) 2. Starter motor lead (black) 14.
5GK14.book Page 34 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU23780 1. 2. 3. 4. 5. Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Spare fuse If a fuse is blown, replace it as follows. 1. Turn the key to “OFF” and turn off the electrical circuit in question. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. Specified fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Radiator fan fuse: 10.
5GK14.book Page 35 Friday, April 11, 2003 1:07 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. 1. Headlight bulb holder 3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the defective bulb. 6 1. Do not touch the glass part of the bulb. EAU24281 Replacing a turn signal light bulb or the tail/brake light bulb 1.
5GK14.book Page 36 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR EAU24360 Front wheel EAU24430 To remove the front wheel EWA10820 WARNING ● ● 1. Turn signal light bulb 2. Remove the defective bulb by pushing it in and turning it counterclockwise. 3. Insert a new bulb into the socket, push it in, and then turn it clockwise until it stops. 4. Install the lens by installing the screws. ECA10680 CAUTION: Do not overtighten the screws, otherwise the lens may break.
5GK14.book Page 37 Friday, April 11, 2003 1:07 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. 2. Lift the wheel up between the fork legs. 6 NOTE: Make sure that the slot in the speedometer gear unit fits over the retainer on the fork leg. 1. Retainer 5.
5GK14.book Page 38 Friday, April 11, 2003 1:07 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. Rear wheel axle pinch bolt 2. Place the motorcycle on the centerstand. 3. Remove the brake caliper by removing the bolts. 4.
5GK14.book Page 39 Friday, April 11, 2003 1:07 PM PERIODIC MAINTENANCE AND MINOR REPAIR 3. Install the brake caliper by installing the bolts. 8. Install the brake torque rod cotter pin. EWA10830 NOTE: Make sure that there is enough space between the brake pads before installing the brake caliper onto the brake disc. 6 WARNING Always use a new cotter pin. 4. Connect the brake torque rod to the brake caliper bracket by installing the bolt and the nut. 5.
5GK14.book Page 40 Friday, April 11, 2003 1:07 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 There is compression. Check the ignition.
5GK14.book Page 41 Friday, April 11, 2003 1:07 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.
5GK14.book Page 1 Friday, April 11, 2003 1:07 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.
5GK14.book Page 2 Friday, April 11, 2003 1:07 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.
5GK14.book Page 3 Friday, April 11, 2003 1:07 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.
5GK14.book Page 4 Friday, April 11, 2003 1:07 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. 7 than 0 °C or more than 30 °C). For more information on storing the battery, see page 6-31. 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.
chapter8 Page 1 Monday, April 14, 2003 8:10 AM 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 (5.7 in) Minimum turning radius: 2900 mm (114.2 in) Weight: With oil and fuel: 283.0 kg (624 lb) Engine: Engine type: Liquid cooled 4-stroke, DOHC Cylinder arrangement: V-type 4-cylinder Displacement: 1198.0 cm³ (73.10 cu.in) Bore × stroke: 76.0 × 66.
5GK14.book Page 2 Friday, April 11, 2003 1:07 PM SPECIFICATIONS 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 (1.348) 4th: 28/26 (1.077) 5th: 26/28 (0.928) Chassis: 8 Frame type: Double cradle Caster angle: 29.0 ° Trail: 119.0 mm (4.
5GK14.book Page 3 Friday, April 11, 2003 1:07 PM SPECIFICATIONS Electrical system: Ignition system: Transistorized coil ignition (digital) Charging system: A.C. magneto Battery: Model: YB16AL-A2 Voltage, capacity: 12 V, 16.0 Ah Headlight: Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: 10.0 A Ignition fuse: 10.0 A Radiator fan fuse: 10.0 A Bulb type: Halogen bulb Bulb voltage, wattage x quantity: Headlight: 12 V, 60.0 W/55.0 W × 1 Tail/brake light: 12 V, 8.0 W/27.
5GK14.book Page 1 Friday, April 11, 2003 1:07 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. Record this number in the space provided.
5GK14.book Page 2 Friday, April 11, 2003 1:07 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.
5GK14.book Page 3 Friday, April 11, 2003 1:07 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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5GK14.book Page 5 Friday, April 11, 2003 1:07 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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5GK14.book Page 7 Friday, April 11, 2003 1:07 PM CONSUMER INFORMATION EAU26661 YAMAHA MOTOR CORPORATION, U.S.A.
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5GK14.book Page 9 Friday, April 11, 2003 1:07 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.
5GK14.book Page 10 Friday, April 11, 2003 1:07 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.
5GK14.book Page 1 Friday, April 11, 2003 1:07 PM INDEX A Accessories and replacement parts...... 6-22 Air filter element, cleaning..................... 6-17 H D Dimmer switch ........................................ 3-4 E Engine break-in....................................... 5-4 Engine oil and oil filter cartridge............ 6-10 Engine, starting a warm .......................... 5-3 Oil level warning light .............................. 3-2 P Parking ................................................
5GK14.book Page 2 Friday, April 11, 2003 1:07 PM INDEX 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................................... 3-4 V Valve clearance, adjusting.................... 6-19 V-Boost..........
OWNER’S MANUAL VMX12S YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2003.04-0.
