VMX12 Service Manual - V-Max Outlaw

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-- GENERAL TORQUE OF UNITS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid tighten fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. A (Nut) 10 mm 12 mm 14mm 17mm 22mm B (Bolt) Nm General torque specifications 6mm 6 0.6 4.3 8 mm 15 1.5 11 30 3.0 22 55 5.5 40 14mm 85 8.5 61 16mm 130 13.0 94 Unit Read Definition Measure mm millimeter meter Length cm centimeter meter Length kilogram gram Weight N Newton 1 x Force Nm Newton meter N x m Torque Meter kilogram m x Torque Pa Paskal Pressure Newton per millimeter Spring rate L Liter Cubic centimeter Volume or Capacity Rotation per minute Engine speed 8-18
CONVERSION TABLES km m m cm mm CONVERSION TABLES Known Metric to inch system Multiplier 7.233 86.80 0.0723 0.8680 Result 0.03527 2.352 0.6214 0.6214 3.281 1.094 0.3937 0.03937 cc 0.0 3 3 8 2 cc 0.06102 t (Iiter 2.1134 lit (liter) 1.057 lit (liter) 0.2642 56.007 14.2234 Centigrade 9/5 + 32 8-19 (US cu in pt (US qt (US gal psi Fahrenheit Known Inch t o metric system Multiplier 0.13826 0.01152 13.831 1.1521 0.4535 28.352 0.4252 1.609 Result mi 1.609 ft 0.3048 0.9141 in 2.54 cm in 25.4 mm (US 29.57 cc cu in 16.387 cc (US 0.4732 lit (liter) (US 0.9461 Iit (liter gal (US 3.785 0.017855 lit (liter) psi 0.07031 5/9 - 32) Centigrade Fahrenheit
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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
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ELECTRIC STARTING SYSTEM NEUTRAL SW
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CHARGING SYSTEM Afcrementioned circ
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CHARGING SYSTEM CHARGINGVOLTAGE TES
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- MEMO- ...........................
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,- IGNITION SYSTEM Aforementioned c
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Troubleshooting Chart IGNITION SYST
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A 13.2 SO 1000 IGNITION SYSTEM IGNI
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IGNITION SYSTEM Removal 1. Remove:
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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: SPECIFICATIONS ModeI Starting Circu
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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