VMX12 Service Manual - V-Max Outlaw

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HOW TO USE THIS MANUAL CONSTRUCTION OF THIS MANUAL This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols") 1 st title : 2nd title : 3rd title : This is a chapter with its symbol on the upper right of each page. Thistitleappearsonthe upper of eachpageon the left of thechaptersymbol. (For the chapter "Periodic inspectionand adjustment" the 3rd title appears.) This is a final title. MANUAL FORMAT All of the procedures in this manual are organized i'n a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference thatcontains comprehensiveexplanationsof alldisassembly, repair, assembly, and inspections. A set of particularly important procedure is placed between a line of asterisks * with each procedure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol An encircled numeral @indicates a part name, and an encircled alphabetical letter data or an alignment mark the others being indicated by an alphabetical letter in a box A condition of a faulty component will precede an arrow symbol and the course of action required the symbol EXPLODED DIAGRAM Each chapter provides exploded diagrams before each disassembly section for ease in identifying correct disassembly and assembly procedures. ................................... ... . i . .. ... .. . . .. ....... .. .................................... . ..... ............ ...... ................ ... . I
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols to are designed as thumb tabs to indicate the chapter's number and content. General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetion Chassis Electrical Troubleshooting Illustrated symbols to are used to identify the specifications appearing in the text. Filling fluid Lubricant Special tool limit, clearance Engine speed V, A Illustrated symbols to in the exploded diagram indicate grade of lubricant and location of lubrication point. Apply engine oil Apply gear oil Apply molybdenum disufide oil wheel bearing grease lightweight lithium-soap base grease Apply molybdenum disulfide grease Apply locking agent (LOCTITE®) Use new one
Page 1 and 2: VMXl2N, NC~K, KC
Page 3 and 4: FOREWORD This Supplementary Service
Page 5 and 6: HOW TO USE THIS MANUAL CONSTRUCTION
Page 7 and 8: .-. CONTENTS GENERAL INFORMATION ..
Page 9 and 10: SPECIAL TOOLS The proper special to
Page 11 and 12: ELECTRICAL Model Rectifier: Model/
Page 13 and 14: I 30 40 50 60"F 0 5 10 15°C ENGINE
Page 15 and 16: INSPECTION AND REPAIR a piece of Pl
Page 17 and 18: P 2 INSPECTION AND REPAIR Main jour
Page 19 and 20: I J5 J6 I INSPECTION AND REPAIR - 1
Page 21 and 22: SHAFT DRIVE Dust cover Bearing hous
Page 23 and 24: LIT-1161 6-08-77 E
Page 25: -- NOTICE This manual was written b
Page 29 and 30: MOTORCYCLE IDENTIFICATION -1- GENER
Page 31 and 32: --- GENERAL SPECIFICATIONS SPECIFIC
Page 33 and 34: -- LECTRICAL Model T.C.I.: Pickup c
Page 35 and 36: FRONT FORK Front fork assembly Inne
Page 37 and 38: ' I 342-024 -9- FRONT FORK 9.Loosen
Page 39 and 40: -11- FRONTFORK 3.Inspect: Damper ro
Page 41 and 42: -- -13- FRONT FORK 6.Install: Retai
Page 43 and 44: -15- FRONT FORK 6.Install: Caliper
Page 45 and 46: CIRCUIT DIAGRAM A.C. Magneto genera
Page 47 and 48: 7 VMX12E/EC WIRING DIAGRAM COLOR CO
Page 49 and 50: LIT-I1616-06-08 I
Page 51 and 52: -- NOTICE This manual was written b
Page 53 and 54: - MOTORCYCLE IDENTIFICATION -1- GEN
Page 55 and 56: Exhaust "A" < Limit > Exhaust < Lim
Page 57 and 58: LIT-1
Page 59 and 60: NOTICE This manual was written by t
Page 61 and 62: MOTORCYCLE I GENERAL INFORMATION RC
Page 63 and 64: Spark Plug: Ty anufacturer Type: Mo
Page 65 and 66: L 1616-04-67 Serr-ice I --
Page 67 and 68: NOTICE This manual was written by t
Page 69 and 70: Being a Yamaha owner, you obviously
Page 71 and 72: CHAPTER 1. GENERAL INFORMATION MOTO
Page 73 and 74: \ IMPORTANT INFORMATION IMPORTANT I
Page 75 and 76: - 4. Fuel Level Gauge P/N YM-01312-
Page 77 and 78:
SPECIAL TOOLS 8. Flywheel Puller P/
Page 79 and 80:
SPECIAL TOOLS 18. Sealant (Quick Ga
Page 81 and 82:
-- SPECIAL TOOLS Final Drive Shaft
Page 83 and 84:
ELECTRICAL. . . . . . . . . . . . .
Page 85 and 86:
-- GENERAL stand pivots MAINTENANCE
Page 87 and 88:
,-- - m VALVE CLEARANCE ADJUSTMENT
Page 89 and 90:
TDC VALVE CLEARANCE ADJUSTMENT 360'
Page 91 and 92:
-- INTAKE MEASURED 0.00-0.05 0.11 0
Page 93 and 94:
FUEL FILTER REPLACEMENT/ INTAKE MAN
Page 95 and 96:
CARBURETOR SYNCHRONIZATION NOTE: Va
Page 97 and 98:
30 40 50 60° F ENGINE OIL LEVEL IN
Page 99 and 100:
COOLANT LEVEL SYSTEM INSPECTION 7.
Page 101 and 102:
FINAL GEAR OIL LEVEL INSPECTION OIL
Page 103 and 104:
-- BRAKE FLUID LEVEL INSPECTION 3.
Page 105 and 106:
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 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 183 and 184:
Page 185 and 186:
3-61 I CRANKCASE ASSEMBLY 1. Apply:
Page 187 and 188:
3-63 Crankshaft on Unsmooth operati
Page 189 and 190:
Page 191 and 192:
ENGINE ASSEMBLY AND ADJUSTMENT CLUT
Page 193 and 194:
Page 195 and 196:
Page 197 and 198:
ENGINE ASSEMBLY AND ADJUSTMENT 4. I
Page 199 and 200:
Page 201 and 202:
3-77 ENGI NE ASSEMBLY AND ADJUSTMEN
Page 203 and 204:
Page 205 and 206:
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 and 238:
AIR CLEANER AND CRANKCASE VENTILATI
Page 239 and 240:
...................................
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
Page 289 and 290:
3. Inspect: leakage By the followin
Page 291 and 292:
1.5 mm (0.06 in) mm (3.94 in) 14 (0
Page 293 and 294:
SHAFT DRIVE 2. Measure: Ring gear s
Page 295 and 296:
Bearing Removal and Reassembly 1. R
Page 297 and 298:
SHAFT DRIVE Where: a = a num eral (
Page 299 and 300:
SHAFT DRIVE Hundredths Round I I 0
Page 301 and 302:
SHAFT DRIVE DRIVE SHAFT Removal 1.
Page 303 and 304:
COOLING SYSTEM ....................
Page 305 and 306:
CIRCUIT DIAGRAM Ignition coil Cance
Page 307 and 308:
ELECTRICAL COMPONENTS (2) Starter r
Page 309 and 310:
ELECTRIC STARTING SYSTEM I Aforemen
Page 311 and 312:
Troubleshooting Chart (2) THE START
Page 313 and 314:
STARTER MOTOR TEST O-ring Brush hol
Page 315 and 316:
,/- ELECTRIC STARTING SYSTEM 5. Ins
Page 317 and 318:
I 22552 I I I I I ELECTRIC STARTING
Page 319 and 320:
ELECTRIC STARTING SYSTEM NEUTRAL SW
Page 321 and 322:
CHARGING SYSTEM Afcrementioned circ
Page 323 and 324:
CHARGING SYSTEM CHARGINGVOLTAGE TES
Page 325 and 326:
- MEMO- ...........................
Page 327 and 328:
,- IGNITION SYSTEM Aforementioned c
Page 329 and 330:
Troubleshooting Chart IGNITION SYST
Page 331 and 332:
A 13.2 SO 1000 IGNITION SYSTEM IGNI
Page 333 and 334:
IGNITION SYSTEM Removal 1. Remove:
Page 335 and 336:
Aforementioned circuit diagram show
Page 337 and 338:
H eadlight Troubleshooting Poor gro
Page 339 and 340:
, MEMO- ...........................
Page 341 and 342:
,--- SIGNAL SYSTEM Aforementioned c
Page 343 and 344:
SIGNAL SYSTEM "01L LEVEL" Warning I
Page 345 and 346:
Troubleshooting Flasher light and i
Page 347 and 348:
-- SIGNAL SYSTEM I Switch Position
Page 349 and 350:
COOLING SYSTEM Aforementioned circu
Page 351 and 352:
(221 COOLING SYSTEM ELECTRIC SW ITC
Page 353 and 354:
A COOLING SYSTEM Thermo-unit.Inspec
Page 355 and 356:
-- /-- Aforementioned circuit diagr
Page 357 and 358:
TROUBLESHOOTING TroubleshootingChar
Page 359 and 360:
-- Troubleshooting Chart (3) pump i
Page 361 and 362:
- FUEL PUMP SYSTEM Cut-out switch D
Page 363 and 364:
Aforementioned circuit diagram show
Page 365 and 366:
V-BOOST SYSTEM O peration There is
Page 367 and 368:
TROUBLESHOOTING TroubleshootingChar
Page 369 and 370:
SERVO MOTOR TEST 1. Disconnect: mot
Page 371 and 372:
SPECIFICATIONS GENERAL SPECIFICATIO
Page 373 and 374:
Model Shock Absorber: Front Shock A
Page 375 and 376:
Model Valve Spring: Inner Spring: F
Page 377 and 378:
Model Shifter: Shifter Type Guide B
Page 379 and 380:
SPECIFICATIONS Model Cooling System
Page 381 and 382:
1 I Part to be Tightened Crankcase
Page 383 and 384:
Model Master Cylinder Inside Diamet
Page 385 and 386:
Electrical Model Voltage: Ignition
Page 387 and 388:
SPECIFICATIONS ModeI Starting Circu
Page 389 and 390:
CONVERSION TABLES km m m cm mm CONV
Page 391 and 392:
LUBRICATION DIAGRAM (2) 8-21 LUBRIC
Page 393 and 394:
LUBRICATION DIAGRAM (4) LUBRICATION
Page 395 and 396:
Fuel pump control unit Relay unit V
Page 397 and 398:
Handlebar switch lead Diode Ignitor
Page 399 and 400:
CABLE ROUTING Fuel filter bracket B
Page 401 and 402:
CANISTER PIPE ROUTING To carburetor
Page 403 and 404:
. . . . . . . . . . . . . . . . . .
Page 405:
PROTECT YOUR INVESTMENT Use Genuine
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VMX12 Service Manual - V-Max Outlaw

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