VMX12 Service Manual - V-Max Outlaw

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CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION ............................................. 2-1 MAINTENANCE INTERVALSCHARTS ........................... 2-1 2-1 PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM ........ GENE RA L MA INTENANC LUBRICATI0N .................... ENGINE ..................................................... VALVE CLEARANCE ADJUSTMENT .......................... CRANKCASE SYSTEM INSPECTION ............. 2-9 FUEL LENE INSPECTION ................................... 2-9 FUEL FILTER REPLACEMENT ............................... 2-10 ............................. 2-10 EXHAUST SYSTEM INSPECTION ............................. 2-10 CANISTER INSPECTION .................................... 2-11 CARBURETOR SYNCHRONIZATION .......................... 2-11 IDLING SPEED ADJUSTMENT ............................... 2-13 THROTTLE CABLE ADJUSTMENT ............................ 2-13 ENGINE L LEVEL INSPECTION ............................ 2-14 ENGINE OIL REPLACEMENT ................................ 2-14 COOLANT LEVEL INSPECTION .............................. 2-16 COOLING SYSTEM INSPECTION ............................. 2-16 COMPRESSION PRESSURE MEASUREMENT ................... CHASSIS .................................................... FINAL GEAR OIL LEVEL INSPECTION ....................... FINAL GEAR OIL REPLACEMENT ............................ AIR FILTER CLEANING .................................... BRAKE FLUID LEVEL INSPECTION .......................... FRONT AND REAR BRAKE PAD INSPECTION .................. FRONT BRAKE ADJUSTMENT ............................... REAR BRAKE ADJUSTMENT ................................ CABLE INSPECTION AND LUBRICATION ...................... BRAKE AND CHANGE AND CLUTCH LEVERS LUBRICATION ............................ CENTERSTAND AND LUBRICATION ............... LUBRICATION ................................ FRONT FORK OIL CHANGE ................................. FRONT FORK ADJUSTMENT ................................ 2-25 REAR SHOCK ABSORBER ADJUSTMENT ...................... RECOMMENDED COMBINATIONS OF THE FRONT FORK AND THE REAR SHOCK ABSORBER SETTINGS................2-28 STEERING HEAD INSPECTION .............................. STEERING HEAD ADJUSTMENT ............................. WHEEL BEARINGS CHECK .................................. TIRES CHECK ............................................. WHEELS CHECK ..........................................
ELECTRICAL. . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34 BATTERY INSPECTION . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35 BRAKE SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . .2-37 SPAR PLUG INSPECTION.. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .2-37 HEADLIGHT BULB REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . 2-38 HEADLIGHT BEAM ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39 FUSE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
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VMXl2N, NC~K, KC
Page 3 and 4:
FOREWORD This Supplementary Service
Page 5 and 6:
HOW TO USE THIS MANUAL CONSTRUCTION
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.-. CONTENTS GENERAL INFORMATION ..
Page 9 and 10:
SPECIAL TOOLS The proper special to
Page 11 and 12:
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
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 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 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: -- SPECIAL TOOLS Final Drive Shaft
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
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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
Page 215 and 216:
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
Page 221 and 222:
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
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
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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
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
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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
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
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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
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
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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- ...........................
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,--- 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
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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
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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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