Yamaha Vmax VMX12 Shop Manual 1986 – 2004
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LANGUAGE:ENGLISH
PAGES:300+
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
Yamaha Vmax VMX12 Shop Manual 1986 – 2004
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe.
- Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
TABLE OF CONTENTS:
Yamaha Vmax VMX12 Shop Manual 1986 – 2004
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION 1-1
FRAME SERIAL NUMBER 1-1
ENGINE SERIAL NUMBER 1-1
IMPORTANT INFORMATION 1-2
ALL REPLACEMENT PARTS 1-2
GASKETS, OIL SEALS, AND O-RINGS 1-2
LOCK WASHERS/PLATES AND COTTER PINS 1-2
BEARINGS AND OIL SEALS 1-2
CIRCLIPS 1-3
SPECIAL TOOLS 1-3
FOR TUNE-UP 1-3
FOR ENGINE SERVICE 1-4
FOR CHASSIS SERVICE 1-8
FOR MIDDLE GEAR SERVICE1-9
FOR ELECTRICAL COMPONENTS1-10
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION2-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS2-1
ENGINE 2-3
VALVE CLEARANCE ADJUSTMENT 2-3
CRANKCASE VENTILATION SYSTEM INSPECTION2-8
FUEL LINE INSPECTION 2-8
FUEL FILTER REPLACEMENT2-9
INTAKE MANIFOLD INSPECTION 2-9
EXHAUST SYSTEM INSPECTION 2-9
CARBURETOR SYNCHRONIZATION 2-10
IDLING SPEED ADJUSTMENT2-12
THROTTLE CABLE ADJUSTMENT2-12
ENGINE OIL LEVEL INSPECTION 2-13
ENGINE OIL REPLACEMENT 2-13
COOLANT LEVEL INSPECTION 2-15
COOLING SYSTEM INSPECTION 2-15
COMPRESSION PRESSURE MEASUREMENT 2-16
CHASSIS 2-17
FINAL GEAR OIL LEVEL INSPECTION 2-17
FINAL GEAR OIL REPLACEMENT 2-17
AIR FILTER CLEANING 2-18
BRAKE FLUID LEVEL INSPECTION 2-19
FRONT AND REAR BRAKE PAD INSPECTION 2-20
FRONT BRAKE ADJUSTMENT2-21
REAR BRAKE ADJUSTMENT 2-21
CABLE INSPECTION AND LUBRICATION 2-22
BRAKE AND CHANGE PEDALS/BRAKE AND CLUTCH LEVERS
LUBRICATION 2-22
CENTERSTAND AND SIDESTAND LUBRICATION 2-22
SWINGARM LUBRICATION 2-22
FRONT FORK OIL CHANGE 2-23
FRONT FORK ADJUSTMENT 2-24
REAR SHOCK ABSORBER ADJUSTMENT 2-25
RECOMMENDED COMBINATIONS OF THE FRONT FORK
AND THE REAR SHOCK ABSORBER SETTINGS2-27
STEERING HEAD INSPECTION 2-27
STEERING HEAD ADJUSTMENT 2-27
WHEEL BEARINGS CHECK 2-30
TIRES CHECK 2-30
WHEELS CHECK2-33
ENGINE OVERHAUL
ENGINE REMOVAL 3-1
PREPARATION FOR REMOVAL 3-1
CARBURETOR 3-2
RADIATOR 3-3
AIR BAFFLE PLATE 3-4
FOOTREST (RIGHT) AND BRAKE PEDAL 3-4
FOOTREST (LEFT) AND CLUTCH RELEASE CYLINDER3-5
EXHAUST PIPE AND MUFFLER 3-6
ENGINE REMOVAL 3-7
ENGINE DISASSEMBLY 3-8
CYLINDER HEAD AND CAMSHAFT 3-8
STARTER IDLE GEARS AND FLYWHEEL 3-11
CLUTCH AND OIL PUMP DRIVE GEAR3-12
WATER PUMP AND THERMOSTATIC VALVE 3-13
STARTER MOTOR AND BREATHER COVER 3-14
OIL PAN AND OIL PUMP 3-14
CRANKCASE DISASSEMBLY 3-15
UPPER CRANKCASE3-16
TRANSMISSION 3-17
LOWER CRANKCASE 3-17
INSPECTION AND REPAIR 3-19
CYLINDER HEAD3-19
VALVE, VALVE GUIDE, AND VALVE SEAT 3-20
CAMSHAFT, CAM CHAIN, AND CAM SPROCKET 3-27
CYLINDER 3-29
PISTON, PISTON RING, AND PISTON PIN 3-29
STARTER DRIVES 3-32
PRIMARY GEARS 3-33
CLUTCH3-33
OIL PUMP 3-35
OIL GALLERY PIPE 3-36
CRANKSHAFT 3-36
BLANCER SHAFT 3-40
TRANSMISSION 3-42
BEARING 3-43
CIRCLIPS AND WASHERS 3-43
MIDDLE GEAR SERVICE3-44
DRIVE AXLE POSITIONING 3-46
REMOVAL 3-50
INSPECTION3-51
ASSEMBLY 3-51
MIDDLE DRIVEN GEAR BEARINGS 3-52
COOLING SYSTEM
COOLANT 4-1
COOLANT FLOW4-1
COOLANT REPLACEMENT 4-2
WATER PUMP 4-5
DISASSEMBLY 4-5
INSPECTION4-5
BEARING AND SEAL REPLACEMENT 4-5
ASSEMBLY 4-7
THERMOSTATIC VALVE4-8
REMOVAL 4-8
INSPECTION AND ASSEMBLY4-8
COOLANT DRAIN VALVE 4-9
DISASSEMBLY 4-9
INSPECTION4-9
ASSEMBLY 4-9
CYLINDER HEAD WATER JACKET JOINT4-10
REMOVAL 4-10
INSPECTION4-10
ASSEMBLY 4-10
RADIATOR AND CONDUIT 4-10
DISASSEMBLY 4-10
INSPECTION4-11
ASSEMBLY 4-12
CARBURETION
CARBURETOR 5-1
SECTION VIEW 5-2
REMOVAL 5-3
DISASSEMBLY 5-3
INSPECTION5-6
ASSEMBLY 5-7
INSTALLATION 5-8
ADJUSTMENT 5-9
THROTTLE CABLE CYLINDER 5-10
ADJUSTMENT 5-10
AIR CLEANER AND CRANKCASE VENTILATION SYSTEM 5-14
FRONT WHEEL6-1
REMOVAL 6-2
INSPECTION6-2
INSTALLATION 6-4
REAR WHEEL 6-6
REMOVAL 6-7
INSPECTION6-7
INSTALLATION 6-8
FRONT AND REAR BRAKE 6-9
CALIPER PAD REPLACEMENT 6-11
CALIPER DISASSEMBLY 6-12
MASTER CYLINDER DISASSEMBLY 6-13
BRAKE INSPECTION AND REPAIR6-16
BRAKE REASSEMBLY 6-17
AIR BLEEDING 6-19
BRAKE DISC INSTALLATION 6-20
HYDRAULIC CLUTCH 6-21
CLUTCH RELEASE DISASSEMBLY 6-22
MASTER CYLINDER DISASSEMBLY 6-22
CLUTCH INSPECITON AND REPAIR 6-23
CLUTCH REASSEMBLY 6-24
AIR BLEEDING 6-25
FRONT FORK 6-27
REMOVAL 6-28
DISASSEMBLY 6-29
INSPECTION6-30
ASSEMBLY 6-31
INSTALLATION 6-33
STEERING HEAD 6-35
REMOVAL 6-36
INSPECTION6-38
INSTALLATION 6-38
REAR SHOCK ABSORBER 6-40
REMOVAL 6-41
INSPECTION6-41
INSTALLATION 6-41
ELECTRICAL
VMX12 CIRCUIT DIAGRAM 7-1
ELECTRICAL COMPONENTS 7-3
ELECTRIC STARTING SYSTEM 7-5
CIRCUIT DIAGRAM 7-5
TROUBLESHOOTING7-7
STARTING CIRCUIT CUT-OFF SYSTEM 7-9
STARTER MOTOR TEST 7-10
BATTERY INSPECTION 7-13
STARTER RELAY TEST 7-13
STARTING CIRCUIT CUT-OFF RELAY TEST 7-14
DIODE TEST7-14
NEUTRAL SWITCH TEST7-15
CHARGING SYSTEM 7-17
CIRCUIT DIAGRAM 7-17
TROUBLESHOOTING7-19
CHARGING VOLTAGE TEST 7-20
BATTERY INSPECTION 7-20
STATOR COIL RESISTANCE TEST7-20
RECTIFIER TEST7-21
IGNITION SYSTEM 7-23
CIRCUIT DIAGRAM 7-23
TROUBLESHOOTING7-25
DESCRIPTION 7-27
OPERATION7-27
IGNITION SPARK GAP TEST 7-28
IGNITION COIL RESISTANCE TEST 7-28
PICKUP COIL RESISTANCE TEST7-29
SPARK PLUG INSPECTION 7-29
PRESSURE SENSOR7-29
LIGHTING SYSTEM 7-31
CIRCUIT DIAGRAM 7-31
LIGHTING TESTS AND CHECKS 7-33
SIGNAL SYSTEM 7-37
CIRCUIT DIAGRAM 7-37
SIGNAL SYSTEM TESTS AND CHECKS 7-39
OIL LEVEL GAUGE TEST7-40
REED SWITCH TEST7-41
SELF-CANCELLING FLASHER SYSTEM TEST 7-41
SWITCHES TEST7-43
SPECIFICATIONS 8-1
GENERAL SPECIFICATIONS 8-1
MAINTENANCE SPECIFICATIONS8-3
GENERAL TORQUE SPECIFICATIONS 8-18
DEFINITION OF UNITS 8-18
LUBRICATION DIAGRAMS 8-19
CABLE ROUTING 8-23
WIRING DIAGRAM
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]