VMX12 Service Manual - V-Max Outlaw

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SPECIAL TOOLS I I 1-5 3. Valve Spring Compressor P/N YM-04019 This tool is needed to remove and install the valve assemblies. 4. Valve Guide Remover (5.5 mm) P/N YM-01122 This tool is used t o remove the valve guides. 5. Valve Guide Reamer (5.5 mm) P/N YM-01196 This tool is used t o new valve guide. 6. Valve Guide Installer P/N YM-01129 This tool is needed t o install the valve guides properly. 7. Valve Seat Cutter Set P/N YM-91043 This tool is needed to resurface the valve seat.
SPECIAL TOOLS 8. Flywheel Puller P/N YU-33270 - Adapter P/N YM-33282 - These tools are used to remove the flywheel. 9.8 mm Wrench Adapter P/N YM-28897 This tool is used to loosen or tighten thecylinder head securing nut. 10. Piston Ring Compressor P/N YM-8037 This tool is used when installing the piston into the cylinder. 11. Water Pump Seal Installer Handle P/N YM-04085-1- Adapter P/N YM-33221- This tool is needed for proper installation of the water pump seal, 12. Piston Pin Puller P/N YU-01304 This tool is used to remove the piston pin. 1-6
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VMXl2N, NC~K, KC
Page 3 and 4:
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
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
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: - 4. Fuel Level Gauge P/N YM-01312-
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
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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
Page 183 and 184:
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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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Page 195 and 196:
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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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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
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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
Page 233 and 234:
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
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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
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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
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
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REMOVAL FRONT FORK Securely support
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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
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-- 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
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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
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
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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
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- MEMO- ...........................
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,- IGNITION SYSTEM Aforementioned c
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Troubleshooting Chart IGNITION SYST
Page 331 and 332:
A 13.2 SO 1000 IGNITION SYSTEM IGNI
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IGNITION SYSTEM Removal 1. Remove:
Page 335 and 336:
Aforementioned circuit diagram show
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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
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. . . . . . . . . . . . . . . . . .
Page 405:
PROTECT YOUR INVESTMENT Use Genuine
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VMX12 Service Manual - V-Max Outlaw

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