Yamaha VMax VMX12N 1985 – 2007 Service Repair Manual

Yamaha V-Max VMX12N 1985 – 2007 Service Repair Manual

 

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your Yamaha. Read and print pages, or copy the entire manual to your hard drive.

405 Pages

 

 

MODEL YEAR:

1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007

 

 

MODEL COVERS:

Yamaha V-Max VMX12N

Yamaha V-Max VMX12NC

 

 

MANUAL COVERS:

GENERAL INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE OVERHAUL
COOLING SYSTEM
CARBURETION
CHASSIS
ELECTRICAL

APPENDICES

 

MOTORCYCLE IDENTIFICATION………………………….. 1-1
VEHICLE IDENTIFICATION NUMBER ……………………. 1-1
ENGINE SERIAL NUMBER…………………………….. 1-1
IMPORTANT INFORMATION……………………………… 1-2
A L L REPLACEMENT PARTS …………………………… 1-2
GASKETS. OIL SEALS. AND O-RINGS ……………………. 1-2
LOCK AND COTTER PINS. . . . . . . . . . . . . . . . . . . 1-2
BEARINGS AND OIL SEALS …………………………… 1-2
CIRCLIPS …………………………………………. 1-3
FOR ENGINE SERVICE ………………………………. 1-4
FOR CHASSIS SERVICE ………………………………. 1-8
FOR MIDDLE GEAR SERVICE………………………….. 1-9
FOR ELECTRICAL COMPONENTS ………………………. 1-10

INTRODUCTION ……………………………………… 2-1
MAINTENANCE INTERVALSCHARTS ……………………… 2-1
PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM …….. 2-1

GENE RA L MAINTENANC LUBRICATI0N ……………….. ENGINE ……………………………………………..

VALVE CLEARANCE ADJUSTMENT ……………………..

CRANKCASE SYSTEM INSPECTION …………. 2-9
FUEL LENE INSPECTION …………………………….. 2-9
FUEL FILTER REPLACEMENT …………………………. 2-10
EXHAUST SYSTEM INSPECTION ……………………….. 2-10
CANISTER INSPECTION ……………………………… 2-11
CARBURETOR SYNCHRONIZATION …………………….. 2-11
IDLING SPEED ADJUSTMENT …………………………. 2-13
THROTTLE CABLE ADJUSTMENT ………………………. 2-13
ENGINE L LEVEL INSPECTION ………………………. 2-14
ENGINE OIL REPLACEMENT ………………………….. 2-14
COOLANT LEVEL INSPECTION ………………………… 2-16
COOLING SYSTEM INSPECTION ……………………….. 2-16
COMPRESSION PRESSURE MEASUREMENT . . . . . . . . . . . . . . . . . . .
CHASSIS …………………………………………….
FINAL GEAR OIL LEVEL INSPECTION …………………..
FINAL GEAR OIL REPLACEMENT ……………………….
AIR FILTER CLEANING ………………………………
BRAKE FLUID LEVEL INSPECTION ……………………..
FRONT AND REAR BRAKE PAD INSPECTION ………………
FRONT BRAKE ADJUSTMENT ………………………….
REAR BRAKE ADJUSTMENT …………………………..

CABLE INSPECTION AND LUBRICATION …………………. BRAKE AND CHANGE AND

CLUTCH LEVERS LUBRICATION……………………….
CENTERSTAND AND LUBRICATION ……………
LUBRICATION …………………………..
FRONT FORK OIL CHANGE ……………………………
FRONT FORK ADJUSTMENT ………………………….. 2-25

REAR SHOCK ABSORBER ADJUSTMENT …………………. RECOMMENDED COMBINATIONS OF THE FRONT FORK

AND THE REAR SHOCK ABSORBER SETTINGS……………. 2-28
STEERING HEAD INSPECTION …………………………
STEERING HEAD ADJUSTMENT ………………………..
WHEEL BEARINGS CHECK …………………………….
TIRES CHECK ………………………………………
WHEELS CHECK ……………………………

ELECTRICAL. . . .. .. . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
CHECK. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .2-34
BATTERY INSPECTION . , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-35
BRAKE SWITCH ADJUSTMENT. . . . . . . . . . . . . . . … . . . . . . .2-37
SPAR PLUG INSPECTION.. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .2-37
HEADLIGHT BULB REPLACEMENT.. . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
HEADLIGHT BEAM ADJUSTMENT. . . . . . . . . . . . . . . . . . . . .. . . . . . . 2-39
FUSE INSPECTION .. . . . . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . .2-39

ENGINE REMOVAL ……………………………………. 3-1
PREPARATION FOR REMOVAL ……………………….. 3-1
CARBURETOR …………………………………….. 3-2
RADIATOR ……………………………………….. 3-3
V-BOOST CONTROL CABLE AND AIR BAFFLE PLATE . . . . . . . . . . . 3-4
FOOTREST (RIGHT) AND BRAKE PEDAL ………………… 3-4
FOOTREST (LEFT) AND CLUTCH RELEASE CYLINDER . . . . . . . . . 3-5
EXHAUST PIPE AND MUFFLER ………………………. 3-6
SERVO MOTOR ……………………………………. 3-7
ENGINE REMOVAL ………………………………… 3-7
V-BOOST …………………………………………. 3-7
ENGINE DISASSEMBLY ………………………………… 3-8
CYLINDER HEAD AND CAMSHAFT …………………….. 3-8
STARTER IDLE GEARS AND FLYWHEEL ……………….. 3-11
CLUTCH AND OIL PUMP DRIVE GEAR ………………… 3-12
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 CRANKCASE ………………………………… 3-16
TRANSMISSION ……………………………………. 3-17
LOWER CRANKCASE ……………………………….. 3-17
INSPECTION AND REPAIR ………………………………
CYLINDER HEAD …………………………………..
VALVE, VALVE GUIDE. AND VALVE SEAT . . . . . . . . . . . . . . . . .3-20
CAMSHAFT. CAM CHAIN. AND CAM SPROCKET . . . . . . . . . . . . . . .
PISTON. PISTON RING. AND PISTON PIN …………………
STARTER DRIVES ………………………………….
PRIMARY GEARS …………………………………..
CLUTCH …………………………………………. 3-33
OIL PUMP ………………………………………… 3-35
OIL GALLERY PIPE …………………………………
CRANKSHAFT ……………………………………..
BLANCER SHAFT …………………………………..
T RANSMISSI0N …………………………………….
BEARING ………………………………………… 3-43
CIRCLIPS AND WASHERS …………………………….
MIDDLE GEAR SERVICE ……………………………….
DRIVE AXLE POSITIONING …………………………..
REMOVAL ……………………………………….. 3-50
INSPECTION ………………………………………. 3-51
ASSEMBLY ………………………………………..
MIDDLE DRIVEN GEAR BEARINGS ……………………. 3-52

ENGINE ASSEMBLY AND ADJUSTMENT ……………………
LOWER CRANKCASE
UPPER CRANKCASE
CRANKCASE ASSEMBLY
TRANSMISSION
OIL PUMP AND OIL PAN
BREATHER COVER AND STARTER MOTOR ……………….
WATER PUMP AND THERMOSTATIC VALVE ……………….
CLUTCH AND OIL PUMP DRIVE GEAR ……………………
FLYWHEEL AND STARTER IDLE GEAR …………………..
CYLINDER HEAD AND CAMSHAFT ……………………..
OIL DELIVERY PIPE AND CYLINDER HEAD . . . . . . . . . . . . . . . . . . .
V-BOOST ………………………………………….
REMOUNTING ENGINE

COOLANT ……………………………………………

COOLANT F LOW ……………………………………

COOLANT REPLACEMENT …………………………….

WATER PUMP ………………………………………… 4-5
D LY …………………………………….. 4-5
INSPECTION ……………………………………….
BEARING AND SEAL REPLACEMENT ……………………. 4-5
ASSEMBLY ……………………………………….. 4-7
THERMOSTATIC VALVE ……………………………….. 4-8
REMOVAL ……………………………………….. 4-8
INSPECTION AND ASSEMBLY …………………………. 4-8
COOLANT DRAIN VALVE ………………………………. 4-9
DISASSEMBLY …………………………………….. 4-9
INSPECTION ………………………………………. 4-9
ASSEMBLY ……………………………………….. 4-9
CYLINDER HEAD WATER JACKET JOINT ……………………
REMOVAL …………………………………………
INSPECTION ………………………………………. 4-10
ASSEMBLY ……………………………………….. 4-10
RADIATOR AND CONDUIT ……………………………… 4-10
DISASSEMBLY …………………………………….. 4-10
INSPECTION 4-11
ASSEMBLY 4-12

CARBURETOR ……………………………………….. 5-1
REMOVAL ……………………………………….. 5-3
DISASSEMBLY ……………………………………… 5-3
INSPECTION ………………………………………. 5-6
ASSEMBLY ……………………………………….. 5-7
INSTALLATION ……………………………………. 5-8
ADJUSTMENT …………………………………….. 5-9
THROTTLE CABLE CYLINDER …………………………… 5-10
ADJUSTMENT …………………………………….. 5-10
V-BOOST ……………………………………………. 5-13
REMOVAL ……………………………………….. 5-13
INSPECTION ………………………………………. 5-13
ADJUSTMENT …………………….. …………….. 5-13
INSTALLATION ……………………………………. 5-15
AIR CLEANER AND CRANKCASE VENTILATION SYSTEM ……..

FRONT WHEEL …………………………………………
REMOVAL ………………………………………….
INSPECTION ………………………………………..
INSTALLATION …………………………………….. 6-4
REAR WHEEL ………………………………………….
REMOVAL …………………………………………. 6-7
INSPECTION ……………………………………….. 6-7
INSTALLATION ……………………………………..
FRONT AND REAR BRAKE………………………………. 6-9
CALIPER PAD REPLACEMENT ………………………….
CALIPER DISASSEMBLY ………………………………
MASTER CYLINDER DISASSEMBLY ……………………..
BRAKE INSPECTION AND ……………………….
BRAKE REASSEMBLY ………………………………..
AIR BLEEDING ……………………………………..
BRAKE DISC INSTALLATION …………………………..
HYDRAULIC CLUTCH …………………………………..
CLUTCH RELEASE DISASSEMBLY……………………….
MASTER CYLINDER DISASSEMBLY ……………………..
CLUTCH INSPECTION AND R………………………
CLUTCH REASSEMBLY ……………………………….
AIR ……………………………………..
FRONT FORK ………………………………………….
REMOVAL …………………………………………
INSPECTION ……………………………………….
ASSEMBLY ………………………………………..
INSTALLATION …………………………………….
STEERING H E A D . ……………………………………..
REMOVAL …………………………………………
INSPECTION ……………………………………….
INSTALLATION …………………………………….
REAR SHOCK ABSORBER ………………………………..
REMOVAL …………………………………………
INSPECTION ……………………………………….
INSTALLATION …………………………………….
FREE PLAY INSPECTION……………………………… 6-44
REMOVAL ………………………………………… 44
INSPECTION ………………………………………. 6-45
INSTALLATION …………………………………….
SHAFT DRIVE………………………………………… 6-47
TROUBLESHOOTING …………………………………
FINAL DRIVE GEAR …………………………………
DRIVE SHAFT…….

CIRCUIT DIAGRAM …………………………… 7-1
ELECTRICAL COMPONENTS ……………………………… 7-3
ELECTRIC STARTING SYSTEM ……………………………. 7-5
CIRCUIT DIAGRAM ………………………………….. 7-6
TROUBLESHOOTING…………………………………. 7-7
STARTER MOTOR TEST ……………………………… 7-10
BATTERY INSPECTION ………………………………. 7-13
STARTER RELAY TEST ……………………………… 7-13
RELAY TEST ……………………………. 7-14
NEUTRAL SWITCH TEST …………………………….. 7-16
SWITCH TEST ……………………………. 7-16
STARTING CIRCUIT CUT-OFF SYSTEM …………………… 7-9
STARTING CIRCUIT CUT-OFF RELAY TEST ………………. 7-14
CHARGINGSYSTEM …………………………………… 7-17
RoUBLESHOOTING ………………………………..
CIRCUIT DIAGRAM …………………………………. 7-17
CHARGING VOLTAGE TEST ………………………….. 7-20
BATTERY INSPECTION………………………………. 7-20
STATOR COIL RESISTANCE TEST ………………………. 7-20
CIRCUIT DIAGRAM …………………………………. 7-23
TROUBLESHOOTING ……………………………….. 7-25
DESCRIPTION …………………………………….. 7-27
OPERATION ………………………………………. 7-27
IGNITION SPARK GAP TEST ………………………….. 7-28
IGNITION COIL RESISTANCE TEST …………………….. 7-28
PRESSURE SENSOR …………………………………. 7-29
PICKUP COIL RESISTANCE TEST ……………………….
LIGHTING SYSTEM ……………………………………. 7-31
CIRCUITDIAGRAM 7-31
LIGHTING TESTS AND CHECKS ……………………….. 7-37
CIRCUIT DIAGRAM …………………………………. 7-37
SIGNAL SYSTEM TESTS AND CHECKS ……………………
L LEVEL GAUGE TEST …………………………….. 7-40
REED SWITCH TEST ………………………………… 7-41
SWITCHES TEST ……………………………………. 7-43

COOLING SYSTEM ……………………………………..
CIRCUIT DIAGRAM …………………………………. 7-45
T R0UBLESHOOTING ……………………………….. 7-47
ELECTRIC FAN AND THERMOSTATIC SWITCH ……………..
THERMO-UNIT AND THERMOMETER ……………………. 7-49
FUEL PUMP SYSTEM ……………………………………
CIRCUIT DIAGRAM …………………………………. 7-51
FUEL PUMP CIRCUIT OPERATION ……………………… 7-53
TROUB LESHOOTING ……………………………….. 7-54
“FUEL” (RESERVE) SWITCH TEST ……………………… 7-57
FUEL PUMP RELAY TEST …………………………….. 7-57
FUEL PUMP TEST ………………………………….. 7-57
FUEL SENDER UNIT TEST ……………………………. 7-58
V-BOOST SYSTEM …………………………………….. 7-59
CIRCUIT DIAGRAM …………………………………. 7-59
V-BOOST SYSTEM ………………………………….. 7-61
TROUB LESHOOTING ……………………………….. 7-64
SERVO MOTOR TEST ……………………………….. 7-66

SPECIFICATIONS ………………………………………. 8-1
GENERAL SPECIFICATIONS ……………………………. 8-1
MAIWTENANCE FICATIONS ……………………….. 8-3
GENERAL TORQUE SPECIFICATIONS……………………….. 8-18
DEFINITION OF UNITS …………………………………. 8-18
CONVERSION TABLES………………………………….. 8-19
LUBRICATION DIAGRAMS ………………………………. 8-20
CABLE ROUTING ……………………………………… 8-24
CONSUMER INFORMATION ……………………………… 8-32
WIRING DIAGRAM…………………………………….. 8-33

 

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly