VMX12 Service Manual - V-Max Outlaw

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COOLANT COOLANT COOLANT FLOW Radiator Coolant drain valve Bypass pipe to the coolant drain valve Bypass pipe to the thermostatic valve Thermostatic valve Water pump To the reservoir tank Thermostat housing Conduit 4- 1 COOLING SYSTEM
COOLANT COOLANT REPLACEMENT 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. When the engine has cooled, open the radiator cap by the foIlowing procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. 1. Place a receptacle under the coolant drain bolt. 2. Remove: *Cover (right) cover Radiator cap *Feed hose (reservoirtank) 3. Align: drain valve "ON" mark with match mark on drain valve housing 4. Remove: *Drain bolt Drain the coolant. 4-2
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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
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BATTERY INSPECTION 2. Remove: 3. In
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-- HEADLIGHT BULD REPLACEMENT NOTE:
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. . . CHAPTER 3. ENGINE OVERHAUL EN
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1 ENGINE REMOVAL ENGINE OVERHAUL EN
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3-3 ENGINE REMOVAL Electrical compo
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3-5 lead 3. Remove: Rear brake swit
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3-7 ENGINE REMOVAL SERVO MOTOR 1. R
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3-9 ENGINE DISASSEMBLY 6. Remove: (
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3-11 1. Remove: *Crankcase cover (l
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3-13 3. Straighten the lock washer
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3-15 ENGINE DISASSEMBLY 4. Straight
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3-17 ENGINE DISASSEMBLY 2. Remove:
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3-19 I 2 3 4 I 2 3 4 n INSPECTION A
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3-21 INSPECTION AND REPAIR 3. Inspe
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3-23 I I I I INSPECTION AND REPAIR
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3-25 INSPECTION AND REPAIR 10. Appl
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3-27 INSPECTION AND REPAIR CAMSHAFT
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mm INSPECTION AND REPAIR Cam Chain
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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 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: -- I' CHAPTER 4. COOLING SYSTEM COO
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
Page 221 and 222: CHAPTER 5. CARBURETION CARBURETOR .
Page 223 and 224: ,,--- SECTION VIEW Pilot air jet No
Page 225 and 226: , CARBURETOR 5. Remove: brackets 6.
Page 227 and 228: CARBURETOR 15. Remove: Rubber caps
Page 229 and 230: CARBURETOR 2. Install: block NOTE:
Page 231 and 232: THROTTLE CABLE CYLINDER THROTTLE CA
Page 233 and 234: THROTTLE CABLE CYLINDER Second step
Page 235 and 236: -- 2. Measure: V-BOOST Betweenthe p
Page 237 and 238: AIR CLEANER AND CRANKCASE VENTILATI
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Page 241 and 242: REMOVAL Securely support the motorc
Page 243 and 244: -- FRONT WHEEL Eye protection is re
Page 245 and 246: REAR WHEEL seat Cylinder bearing se
Page 247 and 248: INSTALLATION When installing the re
Page 249 and 250: FRONT AND REAR BRAKE Air bleed scre
Page 251 and 252: FRONT AND REAR BRAKE BRAKE ONLY: Be
Page 253 and 254: Reservoir tank Band C opper w asher
Page 255 and 256: FRONT AND REAR BRAKE Rear Brake Mas
Page 257 and 258: 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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