VMX12 Service Manual - V-Max Outlaw

More documents

Recommendations

Info

-10- FRONT FORK Removal steps: • Hold the fork leg horizontally. • Clamp the caliper mounting boss of the outer tube securely in a visewith soft jaws. Pull out the inner fork tube from the outer tube by forcefully, butcarefully, with drawing the inner tube. Excessive force will damage the oil seal and/or the bushes. Damage oil seal and bushing must be replaced. \ Avoidbottoming the innertubeintheouter tubeduringthe aboveprocedure, astheoil lock piecewill be damaged. 6. Remove: Oil seal Seal spacer Slide metal Piston metal Damper rod Oil lock piece INSPECTION 1.Inspect: Inner fork tube Outer fork tube Scratches/Bends/Damage Replace. Do not attempt to straighten a bent inner fork tube as this may dangerously weaken the tube. Fork spring free length (limit): 381.5 mm (15.0 in)
-11- FRONTFORK 3.Inspect: Damper rod Wear/Damage Replace. Contamination Blow out all oil passages with compressed air. 4. Inspect: Oil lock piece O-ring (cap bolt) Wear/Damage Replace. ASSEMBLY Reverse the "DISASSEMBLY" procedure. Note the following points. NOTE: In front fork reassembly, be sure to use following new parts. * Piston metal * Slide metal Oil seal Dust seal Make sure that all components are clean before reassembly. 1.lnstall: Damper rod Allow the damper rod to slide slowly down the inner fork tube until it protrudes from the bottom, being careful not to damage the inner fork tube.
Page 1 and 2: VMXl2N, NC~K, KC
Page 3 and 4: FOREWORD This Supplementary Service
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: ' I 342-024 -9- FRONT FORK 9.Loosen
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
Page 55 and 56: Exhaust "A" < Limit > Exhaust < Lim
Page 57 and 58: LIT-1
Page 59 and 60: NOTICE This manual was written by t
Page 61 and 62: MOTORCYCLE I GENERAL INFORMATION RC
Page 63 and 64: Spark Plug: Ty anufacturer Type: Mo
Page 65 and 66: L 1616-04-67 Serr-ice I --
Page 67 and 68: NOTICE This manual was written by t
Page 69 and 70: Being a Yamaha owner, you obviously
Page 71 and 72: CHAPTER 1. GENERAL INFORMATION MOTO
Page 73 and 74: \ IMPORTANT INFORMATION IMPORTANT I
Page 75 and 76: - 4. Fuel Level Gauge P/N YM-01312-
Page 77 and 78: SPECIAL TOOLS 8. Flywheel Puller P/
Page 79 and 80: SPECIAL TOOLS 18. Sealant (Quick Ga
Page 81 and 82: -- SPECIAL TOOLS Final Drive Shaft
Page 83 and 84: ELECTRICAL. . . . . . . . . . . . .
Page 85 and 86: -- GENERAL stand pivots MAINTENANCE
Page 87 and 88: ,-- - m VALVE CLEARANCE ADJUSTMENT
Page 89 and 90:
TDC VALVE CLEARANCE ADJUSTMENT 360'
Page 91 and 92:
-- 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
Page 97 and 98:
30 40 50 60° F ENGINE OIL LEVEL IN
Page 99 and 100:
COOLANT LEVEL SYSTEM INSPECTION 7.
Page 101 and 102:
FINAL GEAR OIL LEVEL INSPECTION OIL
Page 103 and 104:
-- BRAKE FLUID LEVEL INSPECTION 3.
Page 105 and 106:
FRONT BRAKE ADJUSTMENT/REAR BRAKE A
Page 107 and 108:
- /-- FRONT FORK ADJUSTMENT FRONT F
Page 109 and 110:
REAR SHOCK ABSORBER ADJUSTMENT By t
Page 111 and 112:
RECOMMENDED COMBINATIONS OF THE FRO
Page 113 and 114:
STEERING HEAD ADJUSTMENT 9. Remove:
Page 115 and 116:
TIRES CHECK Be sure to install the
Page 117 and 118:
WHEELS CHECK/IGNITION TIMING CHECK
Page 119 and 120:
BATTERY INSPECTION 2. Remove: 3. In
Page 121 and 122:
-- HEADLIGHT BULD REPLACEMENT NOTE:
Page 123 and 124:
. . . CHAPTER 3. ENGINE OVERHAUL EN
Page 125 and 126:
1 ENGINE REMOVAL ENGINE OVERHAUL EN
Page 127 and 128:
3-3 ENGINE REMOVAL Electrical compo
Page 129 and 130:
3-5 lead 3. Remove: Rear brake swit
Page 131 and 132:
3-7 ENGINE REMOVAL SERVO MOTOR 1. R
Page 133 and 134:
3-9 ENGINE DISASSEMBLY 6. Remove: (
Page 135 and 136:
3-11 1. Remove: *Crankcase cover (l
Page 137 and 138:
3-13 3. Straighten the lock washer
Page 139 and 140:
3-15 ENGINE DISASSEMBLY 4. Straight
Page 141 and 142:
3-17 ENGINE DISASSEMBLY 2. Remove:
Page 143 and 144:
3-19 I 2 3 4 I 2 3 4 n INSPECTION A
Page 145 and 146:
3-21 INSPECTION AND REPAIR 3. Inspe
Page 147 and 148:
3-23 I I I I INSPECTION AND REPAIR
Page 149 and 150:
3-25 INSPECTION AND REPAIR 10. Appl
Page 151 and 152:
3-27 INSPECTION AND REPAIR CAMSHAFT
Page 153 and 154:
mm INSPECTION AND REPAIR Cam Chain
Page 155 and 156:
3-31 INSPECTION AND REPAIR 2. Posit
Page 157 and 158:
INSPECTION AND REPAIR I I 3-33 Star
Page 159 and 160:
3-35 INSPECTION AND REPAIR I Clutch
Page 161 and 162:
3-37 INSPECTION AND REPAIR 4. Attac
Page 163 and 164:
3-39 INSPECTION AND REPAIR J2 J3 J4
Page 165 and 166:
3-41 INSPECTION AND REPAIR 3. Insta
Page 167 and 168:
3-43 INSPECTION AND REPAIR Shift Ca
Page 169 and 170:
3-45 MIDDLE GEAR SERVICE Drive axle
Page 171 and 172:
MIDDLE GEAR SERVICE Exam ple: Selec
Page 173 and 174:
3-49 U MIDDLE GEAR SERVICE 6. Tight
Page 175 and 176:
3-51 MIDDLE GEAR SERVICE 6. Remove:
Page 177 and 178:
3-53 MIDDLE GEAR SERVICE 3. Remove:
Page 179 and 180:
3-55 ENGINE ASSEMBLY AND ADJUSTMENT
Page 181 and 182:
TRANSMISSION 3-57 Bearing 1st wheel
Page 183 and 184:
Page 185 and 186:
3-61 I CRANKCASE ASSEMBLY 1. Apply:
Page 187 and 188:
3-63 Crankshaft on Unsmooth operati
Page 189 and 190:
Page 191 and 192:
ENGINE ASSEMBLY AND ADJUSTMENT CLUT
Page 193 and 194:
Page 195 and 196:
Page 197 and 198:
ENGINE ASSEMBLY AND ADJUSTMENT 4. I
Page 199 and 200:
Page 201 and 202:
3-77 ENGI NE ASSEMBLY AND ADJUSTMEN
Page 203 and 204:
Page 205 and 206:
Page 207 and 208:
-- I' CHAPTER 4. COOLING SYSTEM COO
Page 209 and 210:
COOLANT COOLANT REPLACEMENT Do not
Page 211 and 212:
Reservoir Tank Capacity: 0.30 L (0.
Page 213 and 214:
-- I WATER PUMP 3. Install: pump Us
Page 215 and 216:
A 80 (176- B I 95°C THERMOSTATIC V
Page 217 and 218:
CYLINDER HEAD WATER JACKET RADIATOR
Page 219 and 220:
RADIATOR AND CONDUIT 2. Inspect: *V
Page 221 and 222:
CHAPTER 5. CARBURETION CARBURETOR .
Page 223 and 224:
,,--- SECTION VIEW Pilot air jet No
Page 225 and 226:
, CARBURETOR 5. Remove: brackets 6.
Page 227 and 228:
CARBURETOR 15. Remove: Rubber caps
Page 229 and 230:
CARBURETOR 2. Install: block NOTE:
Page 231 and 232:
THROTTLE CABLE CYLINDER THROTTLE CA
Page 233 and 234:
THROTTLE CABLE CYLINDER Second step
Page 235 and 236:
-- 2. Measure: V-BOOST Betweenthe p
Page 237 and 238:
AIR CLEANER AND CRANKCASE VENTILATI
Page 239 and 240:
...................................
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 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 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
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 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
show all

VMX12 Service Manual - V-Max Outlaw

Create successful ePaper yourself

Delete template?

Save as template?