VMX12 Service Manual - V-Max Outlaw

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7-1 I I w w CIRCUIT DIAGRAM CIRCUIT DIAGRAM ELECTRICAL
CIRCUIT DIAGRAM Ignition coil Cancellingunit Spark plug Starter switch Ignition coil "TURN" switch Spark plug "TURN" indicator light Ignition light Spark plug Flasher light Ignition coil Reed switch switch Temperature meter Electric fan Thermo-unit Tachometer Fuse Horn Rectifier with regulator "HORN" switch Main fuse "FUEL" indicator light Battery Fuel sender unit Starter motor "OIL LEVEL" warning indicator light Starter relay "NEUTRAL" indicator light Fuse (IGNITION) Neutral switch "ENGINE STOP" switch Front brake switch V-boost valve control unit Rear brake switch Servo motor "LIGHTS" (Dimmer) switch Clutch switch Headlight Diode "HIGH BEAM" indicator light Sidestand switch Meter light Sidestand relay light Pressure sensor Fuse (HEAD) Ignitor unit Fuse (SIGNAL) Pick-up coil Relay unit "FUEL" (RESERVE) switch Starting circuit cut-off relay Fuel pump relay Flasher relay Fuel pump COLOR CODE B .........Black L .........Blue 0 .........Orange G ........ .Green R .........Red P .........Pink Y .........Yellow W. ........White Br. ....... .Brown Dg ........Dark green Ch ........Chocolate Sb ........Sky blue Gy ....... .Gray ...... ...... ...... ...... ...... ...... LIB. ...... LAN ...... ....... RIG ....... RIB ...... ....... .......Whi Red WIG ...... ...... ...... ...... ..... 7-2
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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
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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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...................................
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REMOVAL Securely support the motorc
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-- FRONT WHEEL Eye protection is re
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REAR WHEEL seat Cylinder bearing se
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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
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: COOLING SYSTEM ....................
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
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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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