VMX12 Service Manual - V-Max Outlaw

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-- INSPECTION AND REPAIR 1. Inspect: Clutch boss splines Scoring/Wear/Damage Replace clutch boss assembly. NOTE: Scoring on the clutch plate splines will cause erratic operation. Friction Plates Inspect: Friction plate Damage/Wear Replace friction plate as a set. 2. Measure: 0 Friction plate thickness Measure at all four points. Out of specification Replace friction plate as a set. Wear Limit: 2.8 mm (0.11 in) Clutch Plates 1. Measure: plate warpage Use the surface plate and the Feeler Gauge Out of specification Replace. Warp Limit: 0.2 mm (0.008 in) Push Rod 1. Measure: rod runout Use V-Blocks and the Dial Gauge (YU-03097). Out of specification Replace. Bending Limit: 0.5 mm (0.02 in) 3-34
3-35 INSPECTION AND REPAIR I Clutch Bearing 1. Inspect: Pitting/Damage Replace. Clutch Spring 1. Inspect: -\ .Clutch spring Wear/Bends/Cracks Replace. 2. Measure: spring free height Out of specification Replace. Clutch SpringMinimum Height: 6.5 mm (0.26 in) 3. Measure: spring warpage Use a surface plate and the Feeler Gauge Out of specification Replace. Warp Limit: 0.1 mm (0.004 in) Clutch Spring Seat 1. Inspect: spring seat Wear/Bends/Damage Replace, OIL PUMP 1. Measure: /Outer rotor clearance Use the Feeler Gauge. Out of specification Replace oil pump assembly. Side Clearance Limit: 0.08 mm (0.0031 in)
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VMXl2N, NC~K, KC
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FOREWORD This Supplementary Service
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HOW TO USE THIS MANUAL CONSTRUCTION
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.-. CONTENTS GENERAL INFORMATION ..
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SPECIAL TOOLS The proper special to
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ELECTRICAL Model Rectifier: Model/
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I 30 40 50 60"F 0 5 10 15°C ENGINE
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INSPECTION AND REPAIR a piece of Pl
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P 2 INSPECTION AND REPAIR Main jour
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I J5 J6 I INSPECTION AND REPAIR - 1
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SHAFT DRIVE Dust cover Bearing hous
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LIT-1161 6-08-77 E
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-- NOTICE This manual was written b
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ILLUSTRATED SYMBOLS (Refer to the i
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MOTORCYCLE IDENTIFICATION -1- GENER
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--- GENERAL SPECIFICATIONS SPECIFIC
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-- LECTRICAL Model T.C.I.: Pickup c
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FRONT FORK Front fork assembly Inne
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' I 342-024 -9- FRONT FORK 9.Loosen
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-11- FRONTFORK 3.Inspect: Damper ro
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-- -13- FRONT FORK 6.Install: Retai
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-15- FRONT FORK 6.Install: Caliper
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CIRCUIT DIAGRAM A.C. Magneto genera
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7 VMX12E/EC WIRING DIAGRAM COLOR CO
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LIT-I1616-06-08 I
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-- NOTICE This manual was written b
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- MOTORCYCLE IDENTIFICATION -1- GEN
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Exhaust "A" < Limit > Exhaust < Lim
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LIT-1
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NOTICE This manual was written by t
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MOTORCYCLE I GENERAL INFORMATION RC
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Spark Plug: Ty anufacturer Type: Mo
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L 1616-04-67 Serr-ice I --
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NOTICE This manual was written by t
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Being a Yamaha owner, you obviously
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CHAPTER 1. GENERAL INFORMATION MOTO
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\ IMPORTANT INFORMATION IMPORTANT I
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- 4. Fuel Level Gauge P/N YM-01312-
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SPECIAL TOOLS 8. Flywheel Puller P/
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SPECIAL TOOLS 18. Sealant (Quick Ga
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-- SPECIAL TOOLS Final Drive Shaft
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ELECTRICAL. . . . . . . . . . . . .
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-- GENERAL stand pivots MAINTENANCE
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,-- - m VALVE CLEARANCE ADJUSTMENT
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TDC VALVE CLEARANCE ADJUSTMENT 360'
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-- INTAKE MEASURED 0.00-0.05 0.11 0
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FUEL FILTER REPLACEMENT/ INTAKE MAN
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CARBURETOR SYNCHRONIZATION NOTE: Va
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30 40 50 60° F ENGINE OIL LEVEL IN
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COOLANT LEVEL SYSTEM INSPECTION 7.
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FINAL GEAR OIL LEVEL INSPECTION OIL
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-- BRAKE FLUID LEVEL INSPECTION 3.
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FRONT BRAKE ADJUSTMENT/REAR BRAKE A
Page 107 and 108: - /-- FRONT FORK ADJUSTMENT FRONT F
Page 109 and 110: REAR SHOCK ABSORBER ADJUSTMENT By t
Page 111 and 112: RECOMMENDED COMBINATIONS OF THE FRO
Page 113 and 114: STEERING HEAD ADJUSTMENT 9. Remove:
Page 115 and 116: TIRES CHECK Be sure to install the
Page 117 and 118: WHEELS CHECK/IGNITION TIMING CHECK
Page 119 and 120: BATTERY INSPECTION 2. Remove: 3. In
Page 121 and 122: -- HEADLIGHT BULD REPLACEMENT NOTE:
Page 123 and 124: . . . CHAPTER 3. ENGINE OVERHAUL EN
Page 125 and 126: 1 ENGINE REMOVAL ENGINE OVERHAUL EN
Page 127 and 128: 3-3 ENGINE REMOVAL Electrical compo
Page 129 and 130: 3-5 lead 3. Remove: Rear brake swit
Page 131 and 132: 3-7 ENGINE REMOVAL SERVO MOTOR 1. R
Page 133 and 134: 3-9 ENGINE DISASSEMBLY 6. Remove: (
Page 135 and 136: 3-11 1. Remove: *Crankcase cover (l
Page 137 and 138: 3-13 3. Straighten the lock washer
Page 139 and 140: 3-15 ENGINE DISASSEMBLY 4. Straight
Page 141 and 142: 3-17 ENGINE DISASSEMBLY 2. Remove:
Page 143 and 144: 3-19 I 2 3 4 I 2 3 4 n INSPECTION A
Page 145 and 146: 3-21 INSPECTION AND REPAIR 3. Inspe
Page 147 and 148: 3-23 I I I I INSPECTION AND REPAIR
Page 149 and 150: 3-25 INSPECTION AND REPAIR 10. Appl
Page 151 and 152: 3-27 INSPECTION AND REPAIR CAMSHAFT
Page 153 and 154: mm INSPECTION AND REPAIR Cam Chain
Page 155 and 156: 3-31 INSPECTION AND REPAIR 2. Posit
Page 157: INSPECTION AND REPAIR I I 3-33 Star
Page 161 and 162: 3-37 INSPECTION AND REPAIR 4. Attac
Page 163 and 164: 3-39 INSPECTION AND REPAIR J2 J3 J4
Page 165 and 166: 3-41 INSPECTION AND REPAIR 3. Insta
Page 167 and 168: 3-43 INSPECTION AND REPAIR Shift Ca
Page 169 and 170: 3-45 MIDDLE GEAR SERVICE Drive axle
Page 171 and 172: MIDDLE GEAR SERVICE Exam ple: Selec
Page 173 and 174: 3-49 U MIDDLE GEAR SERVICE 6. Tight
Page 175 and 176: 3-51 MIDDLE GEAR SERVICE 6. Remove:
Page 177 and 178: 3-53 MIDDLE GEAR SERVICE 3. Remove:
Page 179 and 180: 3-55 ENGINE ASSEMBLY AND ADJUSTMENT
Page 181 and 182: TRANSMISSION 3-57 Bearing 1st wheel
Page 185 and 186: 3-61 I CRANKCASE ASSEMBLY 1. Apply:
Page 187 and 188: 3-63 Crankshaft on Unsmooth operati
Page 191 and 192: ENGINE ASSEMBLY AND ADJUSTMENT CLUT
Page 197 and 198: ENGINE ASSEMBLY AND ADJUSTMENT 4. I
Page 201 and 202: 3-77 ENGI NE ASSEMBLY AND ADJUSTMEN
Page 207 and 208: -- I' CHAPTER 4. COOLING SYSTEM COO
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COOLANT COOLANT REPLACEMENT Do not
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Reservoir Tank Capacity: 0.30 L (0.
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-- I WATER PUMP 3. Install: pump Us
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A 80 (176- B I 95°C THERMOSTATIC V
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CYLINDER HEAD WATER JACKET RADIATOR
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RADIATOR AND CONDUIT 2. Inspect: *V
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CHAPTER 5. CARBURETION CARBURETOR .
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,,--- SECTION VIEW Pilot air jet No
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, CARBURETOR 5. Remove: brackets 6.
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CARBURETOR 15. Remove: Rubber caps
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CARBURETOR 2. Install: block NOTE:
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THROTTLE CABLE CYLINDER THROTTLE CA
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THROTTLE CABLE CYLINDER Second step
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-- 2. Measure: V-BOOST Betweenthe p
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AIR CLEANER AND CRANKCASE VENTILATI
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...................................
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REMOVAL Securely support the motorc
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-- FRONT WHEEL Eye protection is re
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REAR WHEEL seat Cylinder bearing se
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INSTALLATION When installing the re
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FRONT AND REAR BRAKE Air bleed scre
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FRONT AND REAR BRAKE BRAKE ONLY: Be
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Reservoir tank Band C opper w asher
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FRONT AND REAR BRAKE Rear Brake Mas
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FRONT AND REAR BRAKE Caliper Reasse
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FRONT AND REAR BRAKE NOTE: If bleed
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HYDRAULIC CLUTCH CLUTCH RELEASE DIS
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HYDRAULIC CLUTCH 3. Inspect: seal W
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HYDRAULIC CLUTCH i.R epeat steps (e
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REMOVAL FRONT FORK Securely support
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FRO NT FO RK NOTE: Excessive force
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FRONT FORK 3. Tighten: Bolt (cylind
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FRONT FORK 5. Adjust: Front fork ai
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-- REMOVAL Securely support the mot
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INSPECTION 1. Wash the bearing in a
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REAR SHOCK ABSORBER shock absorber
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REAR SHOCK ABSORBER 2. Install: Rea
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SWINGARM FREE PLAY INSPECTION 1. Re
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INSTALLATION When installing the sw
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- SHAFT DRIVE TROUBLESHOOTING The f
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3. Inspect: leakage By the followin
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1.5 mm (0.06 in) mm (3.94 in) 14 (0
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SHAFT DRIVE 2. Measure: Ring gear s
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Bearing Removal and Reassembly 1. R
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SHAFT DRIVE Where: a = a num eral (
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SHAFT DRIVE Hundredths Round I I 0
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SHAFT DRIVE DRIVE SHAFT Removal 1.
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COOLING SYSTEM ....................
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CIRCUIT DIAGRAM Ignition coil Cance
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ELECTRICAL COMPONENTS (2) Starter r
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ELECTRIC STARTING SYSTEM I Aforemen
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Troubleshooting Chart (2) THE START
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STARTER MOTOR TEST O-ring Brush hol
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,/- ELECTRIC STARTING SYSTEM 5. Ins
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I 22552 I I I I I ELECTRIC STARTING
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ELECTRIC STARTING SYSTEM NEUTRAL SW
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CHARGING SYSTEM Afcrementioned circ
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CHARGING SYSTEM CHARGINGVOLTAGE TES
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- MEMO- ...........................
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,- IGNITION SYSTEM Aforementioned c
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Troubleshooting Chart IGNITION SYST
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A 13.2 SO 1000 IGNITION SYSTEM IGNI
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IGNITION SYSTEM Removal 1. Remove:
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Aforementioned circuit diagram show
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H eadlight Troubleshooting Poor gro
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, MEMO- ...........................
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,--- SIGNAL SYSTEM Aforementioned c
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SIGNAL SYSTEM "01L LEVEL" Warning I
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Troubleshooting Flasher light and i
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-- SIGNAL SYSTEM I Switch Position
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COOLING SYSTEM Aforementioned circu
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(221 COOLING SYSTEM ELECTRIC SW ITC
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A COOLING SYSTEM Thermo-unit.Inspec
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-- /-- Aforementioned circuit diagr
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TROUBLESHOOTING TroubleshootingChar
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-- Troubleshooting Chart (3) pump i
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- FUEL PUMP SYSTEM Cut-out switch D
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Aforementioned circuit diagram show
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V-BOOST SYSTEM O peration There is
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TROUBLESHOOTING TroubleshootingChar
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SERVO MOTOR TEST 1. Disconnect: mot
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SPECIFICATIONS GENERAL SPECIFICATIO
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Model Shock Absorber: Front Shock A
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Model Valve Spring: Inner Spring: F
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Model Shifter: Shifter Type Guide B
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SPECIFICATIONS Model Cooling System
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1 I Part to be Tightened Crankcase
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Model Master Cylinder Inside Diamet
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Electrical Model Voltage: Ignition
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SPECIFICATIONS ModeI Starting Circu
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CONVERSION TABLES km m m cm mm CONV
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LUBRICATION DIAGRAM (2) 8-21 LUBRIC
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LUBRICATION DIAGRAM (4) LUBRICATION
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Fuel pump control unit Relay unit V
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Handlebar switch lead Diode Ignitor
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CABLE ROUTING Fuel filter bracket B
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CANISTER PIPE ROUTING To carburetor
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. . . . . . . . . . . . . . . . . .
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PROTECT YOUR INVESTMENT Use Genuine
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VMX12 Service Manual - V-Max Outlaw

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