VMX12 Service Manual - V-Max Outlaw

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6-53 SHAFT DRIVE 2. Remove: Bearing housing Dust cover Ring gear Shim(s) Thrust washer 3. Adjust: G ear lash By the fo low ing adjustm ent steps. G ear lash adjustm ent steps: Select the suitable shims and thrust w asher by the fo low ing chart. Too-little gear lash R educe shim thickness. Too-large gear lash Increase shim thickness. To Add or Reduce Ring G ear Shim Thickness Increase by m ore R educe by m ore than 0.1 mm (0.004 in) than 0.1 mm (0.004 in) gear shim increase. Thrust W asher 1.4 1.5 1.6 Thickness (mm) 1.7 1.8 1.9 2.0 2.1 2.2 2.3 Ring G ear Stopper Clearance M easurem ent 1. Remove: Bearing housing w ith ring gear Refer to “G ear Lash Adjustm ent” section.
SHAFT DRIVE 2. Measure: Ring gear stopper clearance Use the Feeler Gauge Out of specification Adjust. Ring Gear Stopper Clearance : 0.30- 0.60 mm (0.012 0.024 in) Ring gear stopper Ringgear 3. Install: Bearing housing with ring gear Ring Gear Stopper Clearance Adjustment 1. Remove: Ring gear Ring gear stopper Bearing housing Left-hand-threads 2. Select: By the following chart. 3. Install: Shim Thickness I 0.40 0.50 in above list (step Ring Gear Stopper: 9 Nm (0.9 6.5 LOCTIT 4. Measure: Ring gear stopper clearance I 54
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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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3-61 I CRANKCASE ASSEMBLY 1. Apply:
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3-63 Crankshaft on Unsmooth operati
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ENGINE ASSEMBLY AND ADJUSTMENT CLUT
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ENGINE ASSEMBLY AND ADJUSTMENT 4. I
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3-77 ENGI NE ASSEMBLY AND ADJUSTMEN
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-- 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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...................................
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: 1.5 mm (0.06 in) mm (3.94 in) 14 (0
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
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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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