VMX12 Service Manual - V-Max Outlaw

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LIT-11616-10-12
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the VMX12H/VMX12HC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. I 1 VMX12N SERVICE MANUAL:2WE-28197-10 VMXl2F SUPPLEMENTARY SERVICE MANUAL:2WE-28197-11 I I VMX12H/VMX12HC SUPPLEMENTARY SERVICE MANUAL 01995 by Yamaha Motor Co. Ltd. 1st Edition, July 1995 All rights resewed. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
Page 1: VMXl2N, NC~K, KC
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 and 26: -- NOTICE This manual was written b
Page 27 and 28: ILLUSTRATED SYMBOLS (Refer to the i
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
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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
Page 81 and 82:
-- 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
Page 93 and 94:
FUEL FILTER REPLACEMENT/ INTAKE MAN
Page 95 and 96:
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
Page 117 and 118:
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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Page 185 and 186:
3-61 I CRANKCASE ASSEMBLY 1. Apply:
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3-63 Crankshaft on Unsmooth operati
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Page 191 and 192:
ENGINE ASSEMBLY AND ADJUSTMENT CLUT
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Page 195 and 196:
Page 197 and 198:
ENGINE ASSEMBLY AND ADJUSTMENT 4. I
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Page 201 and 202:
3-77 ENGI NE ASSEMBLY AND ADJUSTMEN
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Page 205 and 206:
Page 207 and 208:
-- 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
Page 221 and 222:
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
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-- 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
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FRONT AND REAR BRAKE Air bleed scre
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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
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FRONT AND REAR BRAKE Caliper Reasse
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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
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REMOVAL FRONT FORK Securely support
Page 269 and 270:
FRO NT FO RK NOTE: Excessive force
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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
Page 293 and 294:
SHAFT DRIVE 2. Measure: Ring gear s
Page 295 and 296:
Bearing Removal and Reassembly 1. R
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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
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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
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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
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- ...........................
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,--- SIGNAL SYSTEM Aforementioned c
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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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