VMX12 Service Manual - V-Max Outlaw

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I It is Steering bearings switch MAINTENANCE INTERVALS CHARTS Remarks Check bearings assembly for looseness. Moderately repack every 24,000 km (15,200 mi). Check bearings for smooth rotation. Check specific gravity and breather pipe for proper operation. Check and clean or replace if Initial (600 mi) mi) Medium weight wheel 0 bearing grease 0 0 0 0 Odometer reading 25,000 km 31,000 or or or 25 months 31 months NOTE: farther odometer reading, repeat the above maintenance at the period established; Every 6,000 km (3,800 mi), Every 12,000 km (7,600 mi), and Every 24,000 km (15,200 mi) intervals. *Brake fluid replacement (brakeand clutch): When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add the fluid as required. On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years. 3) Replace the brake (clutch) hoses every four years, or it cracked or damaged. Engine oil: 2-3 0 5 Yamalube 4-cycle Oil or SAE Type SE Motor Oil SAE 1OW30 Type SE Motor Oil
,-- - m VALVE CLEARANCE ADJUSTMENT ENGINE VALVE CLEARANCE ADJUSTMENT Removal 1. Remove: cover (left and right) 2. Remove: .Electrical components board 3. Disconnect: electrical component leads 4. Remove: covers (radiator) (radiator) NOTE: It is not necessary to remove the radiator completely from the motorcycle. 5. Disconnect: plug caps 6. Remove: baffle plate (rear) 7. Remove: head covers NOTE: Be sure you do not lose the oil plugs on the camshaft caps. 2-4
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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
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 and 82: -- SPECIAL TOOLS Final Drive Shaft
Page 83 and 84: ELECTRICAL. . . . . . . . . . . . .
Page 85: -- GENERAL stand pivots MAINTENANCE
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
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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
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H eadlight Troubleshooting Poor gro
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, MEMO- ...........................
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,--- SIGNAL SYSTEM Aforementioned c
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SIGNAL SYSTEM "01L LEVEL" Warning I
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Troubleshooting Flasher light and i
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-- SIGNAL SYSTEM I Switch Position
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COOLING SYSTEM Aforementioned circu
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(221 COOLING SYSTEM ELECTRIC SW ITC
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A COOLING SYSTEM Thermo-unit.Inspec
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-- /-- Aforementioned circuit diagr
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TROUBLESHOOTING TroubleshootingChar
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-- Troubleshooting Chart (3) pump i
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- FUEL PUMP SYSTEM Cut-out switch D
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Aforementioned circuit diagram show
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V-BOOST SYSTEM O peration There is
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TROUBLESHOOTING TroubleshootingChar
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SERVO MOTOR TEST 1. Disconnect: mot
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SPECIFICATIONS GENERAL SPECIFICATIO
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Model Shock Absorber: Front Shock A
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Model Valve Spring: Inner Spring: F
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Model Shifter: Shifter Type Guide B
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SPECIFICATIONS Model Cooling System
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1 I Part to be Tightened Crankcase
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Model Master Cylinder Inside Diamet
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Electrical Model Voltage: Ignition
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SPECIFICATIONS ModeI Starting Circu
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CONVERSION TABLES km m m cm mm CONV
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LUBRICATION DIAGRAM (2) 8-21 LUBRIC
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LUBRICATION DIAGRAM (4) LUBRICATION
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Fuel pump control unit Relay unit V
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Handlebar switch lead Diode Ignitor
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CABLE ROUTING Fuel filter bracket B
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CANISTER PIPE ROUTING To carburetor
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. . . . . . . . . . . . . . . . . .
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PROTECT YOUR INVESTMENT Use Genuine
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VMX12 Service Manual - V-Max Outlaw

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