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VMX12 2001
Yamaha VMX12 2001 User Manual
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ELEC
CHECKING THE SWITCHES
EAS00731
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear
→
Repair or replace.
Improperly connected
→
Properly connect.
Incorrect continuity reading
→
Replace the switch.
396
398
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
Adjusting the Valve Clearance
73
Synchronizing the Carburetors
78
Adjusting the Engine Idling Speed
80
Adjusting the Throttle Cable Free Play
81
Checking the Spark Plugs
82
Checking the Ignition Timing
83
Measuring the Compression Pressure
84
Checking the Engine Oil Level
86
Changing the Engine Oil
87
Measuring the Engine Oil Pressure
88
Checking the Clutch Fluid Level
90
Bleeding the Hydraulic Clutch System
91
Cleaning the Air Filter Element
92
Checking the Carburetor Joints
93
Checking the Vacuum Hoses
93
Checking the Fuel Hoses and Fuel Filter
94
Checking the Crankcase Breather Hose
94
Checking the Exhaust System
95
Checking the Coolant Level
95
Checking the Cooling System
96
Changing the Coolant
97
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
Removing the Connecting Rods and Pistons
206
Checking the Cylinders and Pistons
207
Checking the Piston Rings
208
Checking the Piston Pins
209
Installing the Pistons and Cylinders
212
Transmission
215
Checking the Shift Forks
218
Checking the Shift Drum Assembly
218
Checking the Transmission
219
Installing the Transmission
220
Disassembling the Middle Drive Shaft Assembly
224
Disassembling the Middle Driven Shaft Assembly
224
Checking the Middle Drive Shaft Assembly
225
Checking the Middle Driven Shaft Assembly
226
Assembling the Middle Drive Shaft Assembly
226
Assembling the Middle Driven Shaft Assembly
227
Installing the Middle Gear
229
Adjusting the Middle Gear Backlash
230
Aligning the Middle Gear
233
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
Replacing the Front Brake Pads
295
Replacing the Rear Brake Pads
297
Disassembling the Front Brake Master Cylinder
306
Disassembling the Rear Brake Master Cylinder
306
Checking the Front and Rear Brake
307
Master Cylinders
307
Assembling and Installing the Front Brake Master Cylinder
308
Assembling and Installing the Rear Brake Master Cylinder
310
Disassembling the Front Brake Calipers
317
Disassembling the Rear Brake Caliper
318
Checking the Front and Rear Brake Calipers
319
Assembling and Installing the Front Brake Calipers
320
Assembling and Installing the Rear Brake Caliper
322
Hydraulic Clutch
325
Disassembling the Clutch Master Cylinder
328
Checking the Clutch Master Cylinder
329
Assembling and Installing the Clutch Master Cylinder
330
Disassembling the Clutch Release Cylinder
336
Checking the Clutch Release Cylinder
337
Assembling and Installing the Clutch Release Cylinder
338
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
Handling the Rear Shock Absorber
362
Removing the Rear Shock Absorber Assemblies
362
Checking the Rear Shock Absorber Assemblies
363
Installing the Rear Shock Absorber Assemblies
363
Swingarm
364
Removing the Swingarm
366
Checking the Swingarm
367
Installing the Swingarm
367
Shaft Drive
369
Troubleshooting
369
Checking the Final Drive Oil for Contamination and Checking the Shaft Drive for Leaks
372
Measuring the Ring Gear Backlash
373
Adjusting the Ring Gear Backlash
374
Measuring the Ring-Gear-To-Stopper-Bolt Clearance
375
Adjusting the Ring-Gear-To-Stopper-Bolt Clearance
375
Disassembling the Final Drive Assembly
380
Removing and Installing the Ring Gear Bearings
381
Aligning the Final Drive Pinion Gear and Ring Gear
382
Checking the Drive Shaft
388
Installing the Final Drive Assembly
388
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
Types of Bulbs
399
Checking the Condition of the Bulbs
401
Checking the Condition of the Bulb Sockets
401
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
4
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Yamaha VMX12 2001 Specifications
General
Brand
Yamaha
Model
VMX12 2001
Category
Motorcycle
Language
English
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