VMX12 Service Manual - V-Max Outlaw

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CHAPTER 6. CHASSIS FRONT WHEEL ................................................ REMOVAL ................................................. INSPECTION ............................................... INSTALLATION ............................................ 6-4 REAR WHEEL ................................................. REMOVAL ................................................. 6-7 INSPECTION ............................................... 6-7 INSTALLATION ............................................ FRONT AND REAR BRAKE..................................... 6-9 CALIPER PAD REPLACEMENT ............................... CALIPER DISASSEMBLY .................................... MASTER CYLINDER DISASSEMBLY .......................... BRAKE INSPECTION AND ............................ BRAKE REASSEMBLY ...................................... AIR BLEEDING ............................................ BRAKE DISC INSTALLATION ................................ HYDRAULIC CLUTCH ......................................... CLUTCH RELEASE DISASSEMBLY ............................ MASTER CYLINDER DISASSEMBLY .......................... CLUTCH INSPECTION AND R........................... CLUTCH REASSEMBLY ..................................... AIR ............................................ FRONT FORK ................................................. REMOVAL ................................................ ............................................ INSPECTION .............................................. ASSEMBLY ............................................... INSTALLATION ........................................... STEERING HEAD. ............................................ REMOVAL ................................................ INSPECTION .............................................. INSTALLATION ........................................... REAR SHOCK ABSORBER ...................................... REMOVAL ................................................ INSPECTION .............................................. INSTALLATION ...........................................
.................................................. 6-43 FREE PLAY INSPECTION.................................... 6-44 REMOVAL ................................................ 44 INSPECTION .............................................. 6-45 INSTALLATION ........................................... SHAFT DRIVE................................................ 6-47 TROUBLESHOOTING ....................................... FINAL DRIVE GEAR ....................................... DRIVE SHAFT.............................................
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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
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INSPECTION AND REPAIR I I 3-33 Star
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3-35 INSPECTION AND REPAIR I Clutch
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3-37 INSPECTION AND REPAIR 4. Attac
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3-39 INSPECTION AND REPAIR J2 J3 J4
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3-41 INSPECTION AND REPAIR 3. Insta
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3-43 INSPECTION AND REPAIR Shift Ca
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3-45 MIDDLE GEAR SERVICE Drive axle
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MIDDLE GEAR SERVICE Exam ple: Selec
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3-49 U MIDDLE GEAR SERVICE 6. Tight
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3-51 MIDDLE GEAR SERVICE 6. Remove:
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3-53 MIDDLE GEAR SERVICE 3. Remove:
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3-55 ENGINE ASSEMBLY AND ADJUSTMENT
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TRANSMISSION 3-57 Bearing 1st wheel
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3-59 ENGINE ASSEMBLY AND ADJUSTMENT
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3-61 I CRANKCASE ASSEMBLY 1. Apply:
Page 187 and 188: 3-63 Crankshaft on Unsmooth operati
Page 189 and 190: 3-65 ENGINE ASSEMBLY AND ADJUSTMENT
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
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: AIR CLEANER AND CRANKCASE VENTILATI
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
Page 259 and 260: FRONT AND REAR BRAKE NOTE: If bleed
Page 261 and 262: HYDRAULIC CLUTCH CLUTCH RELEASE DIS
Page 263 and 264: HYDRAULIC CLUTCH 3. Inspect: seal W
Page 265 and 266: HYDRAULIC CLUTCH i.R epeat steps (e
Page 267 and 268: REMOVAL FRONT FORK Securely support
Page 269 and 270: FRO NT FO RK NOTE: Excessive force
Page 271 and 272: FRONT FORK 3. Tighten: Bolt (cylind
Page 273 and 274: FRONT FORK 5. Adjust: Front fork ai
Page 275 and 276: -- REMOVAL Securely support the mot
Page 277 and 278: INSPECTION 1. Wash the bearing in a
Page 279 and 280: REAR SHOCK ABSORBER shock absorber
Page 281 and 282: REAR SHOCK ABSORBER 2. Install: Rea
Page 283 and 284: SWINGARM FREE PLAY INSPECTION 1. Re
Page 285 and 286: INSTALLATION When installing the sw
Page 287 and 288: - 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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