Yamaha VMX12K Manuals

Manuals and User Guides for Yamaha VMX12K. We have 1 Yamaha VMX12K manual available for free PDF download: Supplementary Service Manual

Yamaha VMX12K Supplementary Service Manual

Yamaha VMX12K Supplementary Service Manual (405 pages)

Brand: Yamaha | Category: Motorcycle | Size: 31.32 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  5
- General Information
  8
  - Motorcycle Identification
    8
    
    Vehicle Identification Number
    10
- Specifications
  10
  - General Specifications
    10
  - Maintenance Specifications
    10
    
    Engine
    10
    
    Electrical
    11
- Periodic Inspection and Adjustment
  12
  - Engine
    12
    
    Engine Oil Replacement
    12
- Engine Overhaul
  14
  - Inspection and Repair
    14
    
    Crankshaft and Connecting Rod
    14
    
    Balancer Shaft
    18
  - Middle Gear Service
    20
  - Shaft Drive
    21
Table of Contents

28
- General Information
  29
  - Motorcycle Identification
    29
    
    Engine Serial Number
    29
  - Special Tool
    30
    
    For Chassis Service
    30
- Specifications
  31
  - General Specifications
    31
  - Maintenance Specifications Engine
    32
    
    Chassis
    32
    
    Electrical
    33
- Chassis
  34
  - Front and Rear Brake
    34
  - Front Fork
    35
    
    Removal
    36
    
    Disassembly
    37
    
    Inspection
    38
    
    Assembly
    39
- Electrical
  44
  - Circuit Diagram
    44
    
    Ignition System
    46
  - Digital Ignition Control System Description
    46
General Information . Chapter 1

71
- Chapter 1 . General Information
  
  72
  - Motorcycle Identification
    72
  - Vehicle Identification Number
    72
  - Important Information
    73
  - All Replacement Parts
    73
  - Gaskets, Oil Seals, and O-Rings
    73
  - Bearings and Oil Seals
    73
  - For Engine Service
    75
    
    Special Tools
    76
  - For Chassis Service
    79
  - For Middle Gear Service
    80
  - For Electrical Components
    81
82
- Chapter 2
  
  84
  - Introduction
    84
    
    Periodic Maintenance Emission Control System
    84
  - Periodic Inspections and Adjustments
    84
  - Engine
    87
    
    Valve Clearance Adjustment
    87
    
    Fuel Lene Inspection
    92
    
    System Inspection
    92
    
    Exhaust System Inspection
    93
    
    Fuel Filter Replacement
    93
    
    Canister Inspection
    94
    
    Carburetor Synchronization
    95
    
    Idling Speed Adjustment
    96
    
    Throttle Cable Adjustment
    96
    
    Engine Oil Replacement
    97
    
    Enginel Level Inspection
    97
    
    Coolant Level Inspection
    99
    
    Cooling System Inspection
    99
    
    Compression Pressure Measurement
    100
  - Chassis
    101
    
    Final Gear Oil Level Inspection
    101
    
    Final Gear Oil Replacement
    101
    
    Air Filter Cleaning
    102
    
    Brake Fluid Level Inspection
    103
    
    Front and Rear Brake Pad Inspection
    104
    
    Front Brake Adjustment
    105
    
    Rear Brake Adjustment
    105
    
    Cable Inspection and Lubrication
    106
    
    Centerstand and
    106
    
    Lubrication
    106
    
    Front Fork Adjustment
    107
    
    Front Fork Oil Change
    107
    
    Rear Shock Absorber Adjustment
    109
    
    Recommended Combinations of the Front Fork
    111
    
    Steering Head Adjustment
    111
    
    Steering Head Inspection
    111
    
    Wheel Bearings Check
    114
    
    Tires Check
    115
    
    Wheels Check
    117
Engine Overhaul

123
- Chapter 3
  
  125
  - Engine Overhaul
    125
  - Engine Removal
    125
  - Preparation for Removal
    125
  - Carburetor
    126
  - Radiator
    127
  - Footrest (Right) and Brake Pedal
    128
  - V-Boost Control Cable and Air Baffle Plate
    128
  - Footrest (Left) and Clutch Release Cylinder
    129
  - Exhaust Pipe and Muffler
    130
  - Engine Removal
    131
  - Servo Motor
    131
  - V-Boost
    131
  - Cylinder Head and Camshaft
    132
  - Engine Disassembly
    132
  - Clutch and Oil Pump Drive Gear
    136
  - Water Pump and Thermostatic Valve
    137
  - Oil Pan and Oil Pump
    138
  - Starter Motor and Breather Cover
    138
  - Crankcase Disassembly
    139
  - Upper Crankcase
    140
    
    Lower Crankcase
    141
  - Cylinder Head
    143
    
    Valve, Valve Guide. and Valve Seat
    144
  - Inspection and Repair
    143
  - Camshaft. Cam Chain. and Cam Sprocket
    151
    
    Piston. Piston Ring. and Piston Pin
    153
  - Starter Drives
    156
    
    Clutch
    157
    
    Primary Gears
    157
  - Oil Pump
    159
    
    Crankshaft
    160
    
    Oil Gallery Pipe
    160
    
    Bearing
    164
  - Middle Gear Service
    168
    
    Drive Axle Positioning
    170
    
    Removal
    174
    
    Assembly
    175
    
    Inspection
    175
    
    Middle Driven Gear Bearings
    176
    
    Engine Assembly and Adjustment
    179
207
- Cooling System
  207
- Chapter 4
  
  212
  - Water Pump
    212
    
    Bearing and Seal Replacement
    212
    
    Inspection
    212
    
    Assembly
    213
  - Thermostatic Valve
    215
    
    Inspection and Assembly
    215
    
    Removal
    215
  - Coolant Drain Valve
    216
    
    Assembly
    216
    
    Disassembly
    216
    
    Inspection
    216
  - Cylinder Head Water Jacket Joint
    217
    
    Assembly
    217
    
    Inspection
    217
    
    Removal
    217
  - Radiator and Conduit
    217
    
    Inspection
    218
    
    Assembly
    219
221
- Carburetor
  223
- Chapter 5
  
  224
  - Disassembly
    224
  - Removal
    224
  - Inspection
    227
  - Assembly
    228
  - Adjustment
    230
  - Throttle Cable Cylinder
    231
    
    Adjustment
    231
  - V-Boost
    234
    
    Adjustment
    234
    
    Inspection
    234
    
    Removal
    234
  - Air Cleaner and Crankcase Ventilation System
    237
    
    Front Wheel
    242
    
    Hydraulic Clutch
    260
    
    Steering Head
    278
    
    Rear Shock Absorber
    279
.

302
- Chapter 7
  
  304
  - Circuit Diagram
    304
  - Electrical Components
    306
  - Electric Starting System
    308
    
    Troubleshooting
    310
    
    Starting Circuit Cut-Off System
    312
    
    Starter Motor Test
    313
    
    Battery Inspection
    316
    
    Starter Relay Test
    316
    
    Relay Test
    317
    
    Starting Circuit Cut-Off Relay Test
    317
    
    Neutral Switch Test
    319
    
    Switch Test
    319
  - Chargingsystem Circuit Diagram
    320
    
    Battery Inspection
    323
    
    Charging Voltage Test
    323
    
    Stator Coil Resistance Test
    323
    
    Circuit Diagram
    326
    
    Operation
    330
    
    Ignition Coil Resistance Test
    331
    
    Ignition Spark Gap Test
    331
    
    Pickup Coil Resistance Test
    332
    
    Pressure Sensor
    332
  - Lighting System
    334
    
    Circuit Diagram
    334
    
    Signal System
    341
    
    Signal System Tests and Checks
    342
    
    Reed Switch Test
    344
    
    Switches Test
    346
  - Cooling System Circuit Diagram
    348
    
    Electric Fan and Thermostatic Switch
    351
    
    Thermo-Unit and Thermometer
    352
  - Fuel Pump System
    354
    
    Circuit Diagram
    354
    
    Fuel Pump Circuit Operation
    356
    
    Troubleshooting
    357
    
    Fuel Pump Relay Test
    360
    
    Fuel Pump Test
    360
    
    Fuel" (Reserve) Switch Test
    360
    
    Fuel Sender Unit Test
    361
  - V-Boost System
    364
    
    Troubleshooting
    367
    
    V-Boost System
    367
    
    Servo Motor Test
    369
    
    General Specifications
    371
    
    Specifications
    371
    
    Maiwtenance Fications
    373
    
    General Torque Specifications
    388
    
    Conversion Tables
    389
    
    Lubrication Diagrams
    390
    
    Cable Routing
    395
    
    Consumer Information
    402
- Chapter 8 . Appendices
  
  371

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