VMX12 Service Manual - V-Max Outlaw

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MIDDLE GEAR SERVICE . I DRIVE AXLE POSITIONING When the crankcase assembly and/or the drive axle are replaced, you must position the drive axle in place. Refer to "Drive Pinion Gear Shim Selection and Middle Gear Lash Adjustment" section. Drive pinion gear Driven pinion gear A Drive pinion gear shim Driven pinion gear shim Drive Pinion Gear Shim Selection = 54.5 plus or minus the number stamped on the drive pinion gear. = 53 plus the number stamped on the left- side rear of the upper crankcase. 3-46
MIDDLE GEAR SERVICE Exam ple: Selection of the drive pinion gear shim; Shim Thickness = Distance “A ” - Distance “B ” If the drive pinion gear is stam ped “03” (plus (+ 03) is implied here since only the m inus (-) designations are stam ped alongside the num bers), then: “A” = 53 -- 0.03 = 54.53 NOTE: All stam ped num bers are in hundredths of a mm. If the left-side-rear of the upper crankcase is stam ped then: = 53 + 0.95 = 53.95 Therefore: T=A-B 54.53 53.95 = 0.58 mm calculated shim thickness is 0.58 m m . Because shim can only be selected in 0.05 mm increm ents, use the fo low ing chart to round off the hundredths digit of the calculated thickness and selest the appropriate shim , the above exam ple, the calculated shim thickness of 0.58 mm is rounded off to 0.60 mm. Therefore, you may choose either 4 0.15 mm shims, 2 0.30 m m shims, or 1 0.30 m m and 2 0.15 m m shims as selected from the shim thickness chart below . Shim size are supplied in the fo low - ing thicknesses: Drive Pinion G ear Shim
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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
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- /-- FRONT FORK ADJUSTMENT FRONT F
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REAR SHOCK ABSORBER ADJUSTMENT By t
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RECOMMENDED COMBINATIONS OF THE FRO
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STEERING HEAD ADJUSTMENT 9. Remove:
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TIRES CHECK Be sure to install the
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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 and 158: INSPECTION AND REPAIR I I 3-33 Star
Page 159 and 160: 3-35 INSPECTION AND REPAIR I Clutch
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: 3-45 MIDDLE GEAR SERVICE Drive axle
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
Page 209 and 210: COOLANT COOLANT REPLACEMENT Do not
Page 211 and 212: Reservoir Tank Capacity: 0.30 L (0.
Page 213 and 214: -- I WATER PUMP 3. Install: pump Us
Page 215 and 216: A 80 (176- B I 95°C THERMOSTATIC V
Page 217 and 218: CYLINDER HEAD WATER JACKET RADIATOR
Page 219 and 220: 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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