Yamaha VMX12 2001 Manuals

Yamaha VMX12 2001 Manuals

Manuals and User Guides for Yamaha VMX12 2001. We have 1 Yamaha VMX12 2001 manual available for free PDF download: Service Manual

Yamaha VMX12 2001 Service Manual

Yamaha VMX12 2001 Service Manual (454 pages)

Brand: Yamaha | Category: Motorcycle | Size: 14.32 MB

Table of Contents

Table of Contents

7
- Engine
  6
  - Table of Contents
    7
- General Information
  6
- Periodic Checks and Adjustments
  6
- Specifications
  6
- Chapter 1 General Information
  12
- Motorcycle Identification
  12
  - Vehicle Identification Number
    12
  - Model Code
    12
- Important Information
  13
  - Preparation for Removal and Disassembly
    13
  - Replacement Parts
    13
  - Gaskets, Oil Seals and O-Rings
    13
  - Lock Washers/Plates and Cotter Pins
    14
  - Bearings and Oil Seals
    14
  - Circlips
    14
  - Checking the Connections
    15
- Special Tools
  20
2 Spec

23
- Chapter 2 Specifications
  25
- General Specifications
  25
- Engine Specifications
  26
- Chassis Specifications
  35
- Electrical Specifications
  38
- Conversion Table
  41
- General Tightening Torque Specification
  41
- Tightening Torques
  42
  - Engine Tightening Torques
    42
  - Chassis Tightening Torques
    45
- Lubrication Points and Lubricant Types
  47
  - Engine
    47
  - Chassis
    48
- Cooling System Diagrams
  49
- Oil Flow Diagrams
  51
- Cable Routing
  55
Chapter 3 Periodic Checks and Adjustments

66
- Introduction
  68
- Periodic Maintenance and Lubrication Intervals
  68
- Seats and Side Covers
  70
- Top Cover and Covers
  71
- Air Filter Case and Electrical Components Board
  72
- Engine
  73
- Chassis
  99
  - Adjusting the Front Brake
    99
  - Adjusting the Rear Brake
    100
  - Checking the Brake Fluid Level
    101
  - Checking the Brake Pads
    102
  - Adjusting the Rear Brake Light Switch
    102
  - Checking the Brake Hoses
    103
  - Bleeding the Hydraulic Brake System
    103
  - Adjusting the Shift Pedal
    105
  - Checking the Final Drive Oil Level
    105
  - Changing the Final Drive Oil
    106
  - Checking and Adjusting the Steering Head
    107
  - Checking the Front Fork
    109
  - Adjusting the Front Fork Legs
    109
  - Adjusting the Rear Shock Absorber Assemblies
    111
  - Checking the Tires
    112
  - Checking the Wheels
    114
  - Checking and Lubricating the Cables
    115
  - Lubricating the Levers and Pedals
    115
  - Lubricating the Sidestand
    116
  - Lubricating the Centerstand
    116
  - Lubricating the Rear Suspension
    116
- Chk Adj
  117
- Electrical System
  117
  - Checking the Battery
    117
  - Checking the Fuses
    121
  - Replacing the Headlight Bulb
    122
  - Adjusting the Headlight Beam
    124
- Eng
  126
Chapter 4 Engine

127
- Engine Removal
  131
- Exhaust Pipe, Muffler and Air Baffle Plates
  131
- Brake Pedal, Footlest (Right), Master Cylinder and Ground Lead
  132
- Leads, Cables and Hoses
  133
- Engine Mounting Bolts
  134
- Installing the Engine
  136
- Camshaft
  137
  - Cylinder Head Covers
    137
  - Camshafts
    139
  - Removing the Camshafts
    140
  - Checking the Camshafts
    141
  - Checking the Timing Chain, Camshaft Sprockets
    143
  - And Timing Chain Guides
    143
  - Checking the Timing Chain Tensioner
    143
  - Installing the Camshafts
    144
- Cylinder Heads
  151
  - Removing the Cylinder Heads
    151
  - Checking the Cylinder Heads
    152
  - Installing the Cylinder Head
    153
- Valves and Valve Springs
  154
  - Removing the Valves
    155
  - Checking the Valves and Valve Guides
    156
  - Checking the Valve Seats
    158
  - Checking the Valve Springs
    160
  - Checking the Valve Lifters
    161
  - Installing the Valves
    161
- Clutch
  163
  - Crankcase Cover (Right Side)
    163
  - Clutch Assembly
    164
  - Removing the Clutch
    166
  - Checking the Friction Plates
    166
  - Checking the Clutch Plates
    167
  - Checking the Clutch Spring Plate
    167
  - Checking the Clutch Housing
    168
  - Checking the Clutch Boss
    168
  - Checking the Pressure Plate
    168
  - Checking the Clutch Push Rods
    169
  - Checking the Primary Drive
    169
  - Installing the Clutch
    169
- Shift Shaft
  172
  - Generator Rotor Cover
    172
  - Shift Shaft and Stopper Lever
    173
  - Checking the Shift Shaft
    174
  - Checking the Stopper Lever
    174
  - Installing the Shift Shaft
    174
- Generator
  176
  - Stator Coil Assembly
    176
  - Generator
    178
  - Removing the Generator
    179
  - Checking the Starter Clutch
    180
  - Installing the Generator
    181
- Oil Pan and Oil Pump
  182
  - Oil Pump
    184
  - Removing the Oil Pan
    186
  - Checking the Oil Pump
    186
  - Checking the Relief Valve
    187
  - Checking the Oil Strainer
    187
  - Assembling the Oil Pump
    188
  - Installing the Oil Pan
    189
- Crankcase
  192
  - Separating the Crankcase
    193
  - Assembling the Crankcase
    194
- Crankshaft
  197
  - Removing the Crankshaft Assembly
    198
  - Checking the Crankshaft
    198
  - Checking the Balancer Shaft
    201
  - Installing the Balancer Shaft
    204
- Connecting Rods and Pistons
  205
- Transmission
  215
- Cool
  237
5 Cool

238
- Chapter 5 Cooling System
  240
- Radiator and Radiator Hoses
  240
  - Checking the Radiator
    242
  - Installing the Radiator
    242
- Thermostat Assembly and Conduit
  243
  - Checking the Thermostat
    247
  - Checking the Radiator Cap
    248
  - Assembling the Thermostat Assembly
    248
  - Installing the Thermostat Assembly
    249
- Water Pump
  250
  - Disassembling the Water Pump
    253
  - Checking the Water Pump
    253
  - Assembling the Water Pump
    255
  - Installing the Water Pump
    256
- Carb
  258
- Chas
  273
Chapter 7 Chassis

274
- Front Wheel and Brake Discs
  276
- Disassembling the Front Wheel
  279
- Removing the Front Wheel
  279
- Checking the Front Wheel
  280
- Checking the Brake Discs
  281
- Checking the Speedometer Gear Unit
  283
- Installing the Front Wheel
  283
- Adjusting the Front Wheel Static Balance
  284
- Rear Wheel and Brake Disc
  287
  - Removing the Rear Wheel
    290
  - Checking the Rear Wheel
    291
  - Checking the Rear Wheel Drive Hub
    291
  - Installing the Rear Wheel
    291
  - Adjusting the Rear Wheel Static Balance
    292
- Front and Rear Brakes
  293
- Hydraulic Clutch
  325
- Front Fork
  340
  - Removing the Front Fork Legs
    343
  - Disassembling the Front Fork Legs
    344
  - Checking the Front Fork Legs
    345
  - Assembling the Front Fork Legs
    346
  - Installing the Front Fork Legs
    349
- Handlebar
  350
  - Removing the Handlebar
    353
  - Checking the Handlebar
    353
  - Installing the Handlebar
    354
- Steering Head
  356
  - Removing the Lower Bracket
    358
  - Checking the Steering Head
    358
  - Installing the Steering Head
    359
- Rear Shock Absorber
  361
- Swingarm
  364
  - Removing the Swingarm
    366
  - Checking the Swingarm
    367
  - Installing the Swingarm
    367
- Shaft Drive
  369
- Elec
  390
Chapter 8 Electrical System

391
- Electrical Components
  393
- Switches
  395
  - Checking Switch Continuity
    395
- Checking the Switches
  397
- Checking the Bulbs and Bulb Sockets
  399
- Ignition System
  402
  - Circuit Diagram
    402
  - Troubleshooting
    403
- Electric Starting System
  407
  - Circuit Diagram
    407
  - Starting Circuit Cutoff System Operation
    408
  - Troubleshooting
    409
- Starter Motor
  413
  - Checking the Starter Motor
    415
  - Assembling the Starter Motor
    416
- Charging System
  418
  - Circuit Diagram
    418
  - Troubleshooting
    419
- Lighting System
  421
  - Circuit Diagram
    421
  - Troubleshooting
    422
  - Checking the Lighting System
    423
- Signaling System
  426
  - Circuit Diagram
    426
  - Troubleshooting
    428
  - Checking the Signaling System
    429
- Cooling System
  435
- Fuel Pump System
  439
  - Circuit Diagram
    439
  - Fuel Pump Circuit Operation
    440
  - Troubleshooting
    441
  - Checking the Fuel Pump
    444
- Trbl Shtg
  445
Trbl Shtg

446
- Troubleshooting Trbl
  446
- Chapter 9
  449
- Electrical Systems
  449
- Engine
  449
- Fuel System
  449
- Incorrect Engine Idling Speed
  449
  - Engine
    450
  - Fuel System
    450
- Starting Problems
  449
- Faulty Clutch
  450
  - Clutch Slips
    450
  - Clutch Drags
    450
- Faulty Gear Shifting
  450
  - Shifting Is Difficult
    450
  - Shift Pedal Does Not Move
    450
  - Jumps out of Gear
    450
- Poor Medium-And-High-Speed Performance
  450
- Overcooling
  451
- Overheating
  451
  - Engine
    451
  - Cooling System
    451
  - Fuel System
    451
  - Chassis
    451
  - Electrical Systems
    451
- Poor Braking Performance
  451

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