VMX12 Service Manual - V-Max Outlaw

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CHAPTER 8. APPENDICES SPECIFICATIONS .............................................. 8-1 GENERAL SPECIFICATIONS .................................. 8-1 MAIWTENANCE FICATIONS ............................. 8-3 GENERAL TORQUE SPECIFICATIONS............................. 8-18 DEFINITION OF UNITS ........................................ 8-18 CONVERSION TABLES......................................... 8-19 LUBRICATION DIAGRAMS ..................................... 8-20 CABLE ROUTING ............................................. 8-24 CONSUMER INFORMATION .................................... 8-32 WIRING DIAGRAM............................................ 8-33
SPECIFICATIONS GENERAL SPECIFICATIONS Engine Starting Number Vehicle Identification Number Dimensions: I Length OveraI I Width Overall Height Seat Height Wheelbase Minimum Ground Clearance Basic Weight: Weight Oil and Full Fuel Tank SPECIFICATIONS Minimum Turning Radius: Engine: Engine Type CyIinder Arrangement Displacement Bore x Stroke Compression Ratio Compression Pressure Starting System Lubrication System: Oil Type or Grade: Engine Oil 30 40 50 60°F 0 5 10 Final Gear Oil Oil Capacity: Engine Oil: Periodic Oil Change With Oil Filter Replacement Total Amount Final Gear Case: Total Amount Radiator Capacity: Including All routes) Air Filter: Fuel: 1 Tank Capacity: Total Reserve APPENDICES 1FK-000101 F 01 2,300 mm (90.6 in) 795 mm (31.3 in) 1,160 mm (45.7 in) 765 mm (30.1 in) 1,590 mm (62.6 in) 145 mm 5.7 in) 274 (604 I 275 (606 2,790 mm 10in) Liquid cooled 4-stroke gasoline, DOHC V-4 cylinder 1,198 76 x 66 mm (2.992 x 2.598 in) 10.5 : 1 1,422 4.5 ,206 psi) Electric starter Wep sump 4-cycle oil or SAE type SE motor oil 5°C (40°F)) temperature does not go below SAE type SE motor oil (If temperature does not go above 15°C (60°F)) SAE 80 API gear oil 3.5 L (3.1 Imp qt, 3.7 US qt) 3.8 L (3.3 Imp qt, 4.0 US qt) 4.7 L (4.1 Imp qt, 5.0 US qt) 0.2 L (0.18 Imp qt, 0.21 US qt) 3.05 L (2.69 Imp qt, 3.22 US qt) Dry type element Regular gasoline 15.0 L (3.3 Imp gal, 4.0 US gal) 3.0 L (0.66 Imp gal, 0.80 US gal)
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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
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Reservoir tank Band C opper w asher
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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
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HYDRAULIC CLUTCH CLUTCH RELEASE DIS
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HYDRAULIC CLUTCH 3. Inspect: seal W
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HYDRAULIC CLUTCH i.R epeat steps (e
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REMOVAL FRONT FORK Securely support
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FRO NT FO RK NOTE: Excessive force
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FRONT FORK 3. Tighten: Bolt (cylind
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FRONT FORK 5. Adjust: Front fork ai
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-- REMOVAL Securely support the mot
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INSPECTION 1. Wash the bearing in a
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REAR SHOCK ABSORBER shock absorber
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REAR SHOCK ABSORBER 2. Install: Rea
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SWINGARM FREE PLAY INSPECTION 1. Re
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INSTALLATION When installing the sw
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- 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
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: SERVO MOTOR TEST 1. Disconnect: mot
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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