VMX12 Service Manual - V-Max Outlaw

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MOTORCYCLE IDENTIFICATION -1- GEN GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFlCATlON NUMBER The vehicle identification number is stamped into the right side of the steering pipe. Starting serial number: JYA2WEE0 TA050101 (USA) JYA2WFC0 TA012101 (California) The vehicle identification number is used to identify your motorcycle and may be used to register your motorcycle with the licensing authority in your state. FRAME SERIAL NUMBER The frame serial number is stamped into the right side of the steering pipe. Starting serial number: 1 2EN-042101 (EUR) I I NOTE: The first three digits of these numbers are for model identifications; the remaining digits are the unit production number. ENGINE SERIAL NUMBER The engine serial number is stamped into the crankcase. Starting serial number: 2WE-050101 (USA) 2WF-012101 (California)I2EN-042101 (EUR) NOTE: The first three digits of these numbers are for model identification; the remaining digits are the unit production number. Designs and specifications are subject to change without notice.
SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. FOR ENGINE SERVICE -2- SPECIAL TOOLS GEN Refer to the list provided to avoid errors when placing an order. YM- P/N. 90890- Oil filter wrench YU-38411 P/N 1426 Exceptfor US,CDN This tool is used to remove and install the oil Ifilter.
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: .-. CONTENTS GENERAL INFORMATION ..
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 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
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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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Page 185 and 186:
3-61 I CRANKCASE ASSEMBLY 1. Apply:
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3-63 Crankshaft on Unsmooth operati
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Page 191 and 192:
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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Page 201 and 202:
3-77 ENGI NE ASSEMBLY AND ADJUSTMEN
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Page 205 and 206:
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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
Page 253 and 254:
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
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HYDRAULIC CLUTCH i.R epeat steps (e
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REMOVAL FRONT FORK Securely support
Page 269 and 270:
FRO NT FO RK NOTE: Excessive force
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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
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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
Page 287 and 288:
- 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
Page 295 and 296:
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 ....................
Page 305 and 306:
CIRCUIT DIAGRAM Ignition coil Cance
Page 307 and 308:
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
Page 331 and 332:
A 13.2 SO 1000 IGNITION SYSTEM IGNI
Page 333 and 334:
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
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SIGNAL SYSTEM "01L LEVEL" Warning I
Page 345 and 346:
Troubleshooting Flasher light and i
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-- SIGNAL SYSTEM I Switch Position
Page 349 and 350:
COOLING SYSTEM Aforementioned circu
Page 351 and 352:
(221 COOLING SYSTEM ELECTRIC SW ITC
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A COOLING SYSTEM Thermo-unit.Inspec
Page 355 and 356:
-- /-- Aforementioned circuit diagr
Page 357 and 358:
TROUBLESHOOTING TroubleshootingChar
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-- Troubleshooting Chart (3) pump i
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- 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
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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
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VMX12 Service Manual - V-Max Outlaw

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