![Yamaha VMX12HC (1995) [14/405] Overhaul](/img/pdf.png)
Yamaha VMX12HC (1995) [14/405] Overhaul
![Yamaha VMX12HC (1995) [14/405] Overhaul](/views2/1121404/page14/bge.png)
INSPECTION AND REPAIR
ENGINE OVERHAUL
INSPECTION AND REPAIR
CRANKSHAFT AND CONNECTING
ROD
1.Measure:
Runout (crankshaft)
Out
of
specification Replace.
Runout:
Less than
0.03
mm
(0.0012
in)
2.1
nspect:
Main journal surfaces
Crank pin surfaces
Bearing surfaces
Wear/Scratches
Replace.
3.
Measure:
Oil clearance (main journal)
Out of specification
Replace bearing.
0.020 ~
0.038
mm
(0.0008 ~
0.0015
in)
Measurement steps:
Do not interchange the bearings and con
-
necting rod. They must be installed in their
original positions, or the correct oil clear
-
ance may not be obtained causing engine
damage.
the bearings, main journals
and
bearing portions of the crankcase.
the crankcase (upper) on a bench
in
an
upside down position.
the
upper
half
of
the
bearings
and
the crankshaft into the crankcase (upper).
Align the projection of the bearing with the
notch
in
the crankcase.
N
O
TE
:
-7-
Содержание
- Front cover 1
- Vmx12h c supplemental service manual 2
- Foreword 3
- Notice 4
- Construction of this manual 5
- Exploded diagram 5
- Important features 5
- Manual format 5
- Illustrate 6
- Symbols 6
- Contents 7
- General information 8
- For engine service 9
- Engine 10
- General specifications 10
- General specifications maintenance specifications 10
- Maintenance specifications 10
- Specifications 10
- 0 0 in 11
- Maintenance specifications 11
- Engine 12
- Engine oil replacement 12
- Periodic inspection and adjustment 12
- Engine overhaul 14
- Inspection and repair 14
- Overhaul 14
- Inspectio n and repair 15
- Inspection and repair 16
- Inspectio n and repair 17
- Crankcase m8 18
- Inspection and repair 18
- Measurement steps 18
- Mm 0 008 18
- Oil clearance 18
- Service 20
- Chassis 21
- Co ltd 22
- Vmx12e c supplemental service manual 23
- Foreword 24
- Necessaryto usethis supplementary service manual together with the following manual 24
- This supplementary service manual has been prepared to introduce new service and data for the vmx12e vmx12ec forcomplete service information procedure 24
- Notice 25
- Particularly important information 25
- How to 26
- Manual 26
- Are designed as thumb tabs to indicate the chapter s number and content 27
- Are used to ide 27
- Illustrated symbols 27
- Illustrated symbols refer to the illustration 27
- In the exploded diagram indicate grad 27
- Lubricant and loc 27
- Lubrication point 27
- Tify the specifications appearing in th 27
- General information 29
- Chassi 30
- Service 30
- Specifications 31
- Chassis 32
- Maintenance specifications 32
- Lectrical 33
- Output 33
- Windin 33
- Chassis 34
- Front and rear brake 34
- Rear brake 34
- Removal 36
- Support the fork before loosening the pinch bolts 37
- Take care not to scratch the inner tube 37
- Front fork 38
- Down the inner fork tube unti 39
- Frontfork 39
- Protrudes from the bottom being careful no 39
- The damper ro 39
- Frontfork 40
- Electrical 44
- Circuit diagram 45
- Ignitio 46
- Ignition system 46
- System 46
- Vmx12e e 47
- Wiring diagram 47
- Co ltd 48
- Vmx12u c supplemental service manual 49
- Foreword 50
- Necessary to use this suppleme 50
- Tary service manual together with following manual 50
- This supplementary service manual has been prepared to introduce new service and new data for the vmx12u uc for complete information on service procedures 50
- Notice 51
- Particularly important information 51
- Use this manual 51
- Illustrated symbols refe 52
- Illustration 52
- General 53
- General information 53
- Motorcycle identification 53
- Appendices 54
- Fications 54
- Vmx12s c supplemental service manual 57
- Foreword 58
- Division 59
- How to us 59
- Manual 59
- Notice 59
- Particularly important information 59
- Chapter 60
- Content 60
- Designe 60
- Illustrated symbols refer to the illustration 60
- Indicat 60
- Engine serial number 61
- Gaoool01 61
- Gaoool01 vmx 61
- General information 61
- Number 61
- Vehicle identification number 61
- Withou 61
- Appendices 62
- Printe 64
- Vmx12n c service manual 65
- Manual 67
- Notice 67
- Are used to identify the specificationsappearing in the text 68
- Designe 68
- Gram indicate grad 68
- Illustrated 68
- Illustrated symbols 68
- Illustrated symbols refer to the illustration 68
- In the exploded di 68
- Lubricant and location of lubrication point 68
- Thumb tabs to indicate the chapter s number and content 68
- Authentic not artificia 69
- Yamaha 69
- Chapte 71
- Chapter 1 general information 71
- General information 71
- Motorcycle identification 72
- Important information 73
- Information 73
- Special tools 74
- Specia 76
- Specia 77
- Specia 78
- Specia 79
- Specia 80
- Specia 81
- Chapter 2 periodic inspections and adjustments 82
- For farther odometer reading repeat the above maintenanc 84
- Important especially important are the maintenence services related to emissions control these controls not only function to ensure cleaner air but are also 84
- Information necessary to perform recommended inspectionsand adjustments these preventive maintenance procedures if followed will ensure more reliable vehicle operation and 84
- Intervals 84
- Intervalscharts 84
- Introduction 84
- Longer servic 84
- Maintenance 84
- Maintenance intervals charts 84
- Mi and 84
- New vehicles that are being prepared for sale 84
- Periodic inspections and adjustments 84
- Periodic maintenance emission control system 84
- Proper periodic maintenanc 84
- Service 84
- Technicians should be familiar with this entire chapter applies to vehicles already in servic 84
- The need for costly overhaul work will be greatly reduced this information 84
- The period established 84
- This chapter includes 84
- To proper engine operation and maximum performance in the following maintenance tables the services related to emissions control are grouped separately 84
- Maintenance intervals charts 85
- Check the brake fluid level and add the flui 86
- Cracked or damaged engin 86
- Every 12 000 k 86
- Every 24 000 k 86
- Every two years 86
- Farther odometer reading repeat the above maintenanc 86
- Maintenance intervals charts 86
- Mi and 86
- Mi intervals 86
- On the inner parts 86
- Replacethe brake clutch hoses every four years o 86
- Required 86
- The master cylinder and caliper cylinder replace the oi 86
- The period established 86
- When disassembling the master cylinder or caliper cylinder replace the brake fluid normally brake fluid replacement brake and clutch 86
- Engine 87
- Valve clearance adjustment 87
- Valve clearance adjustment 89
- Adjustment 90
- Clearanc 90
- Valve clearance adjustment 91
- Crankcase ventilation system inspection fuel line inspection 92
- Fuel filter replacement intake manifold inspection exhaust system inspection 93
- Caniste 94
- Canister inspection for california 94
- Carburetor synchronization 94
- R etor synchronization 94
- Carburetor synchronization 95
- Idling speed adjustm ent thro ttle cable adjustm ent 96
- Eng ine o i 97
- Eng ine o il replacem ent 97
- Level inspectio n 97
- Eng in 98
- Replacem ent 98
- Coolant level 99
- System inspection 99
- Compression pressure measurement 100
- Chassis 101
- Final gear oil level inspection 101
- Oil replacement 101
- Level inspection 103
- Front and rear brake pad inspection 104
- Front brake adjustment rear brake adjustment 105
- Brake and change pedals brake and clutch levers lubrication 106
- Cable inspectionand lubrication 106
- Cable inspectionand lubrication brake and change 106
- Cable inspectionand lubrication steps 106
- Centerstand and sidestand lubrication 106
- Medium weight wheel bearin 106
- Sae 10w30 moto 106
- Stand and sidestand lubrication swingarm lubrication pedals brake and clutch levers lubrication center 106
- Swingarm lubrication 106
- Yamaha chain and cable lub 106
- Yamaha chain and cable lube or sae 10w30 moto 106
- Ymaha chain and cable lube or sae 10w30motor oil 106
- Change 107
- Diminishe 107
- Front for 107
- Front fork adjustment 107
- Suppor 107
- Front fork adjustment 108
- Absorber adjustment 109
- Absorber adjustment 110
- Head adjustment 112
- Steering head adjustment 113
- Tires check 115
- Adjuste 116
- Injury 116
- Should 116
- Electrical 117
- Yu 08037 117
- Batter 118
- Inspection 118
- Always charge a new battery befor 119
- Amps 10 hrs specific gravity 119
- Battery inspection 119
- Cause battery electrolyt 119
- Ensure maximum performance 119
- Routed correctly 119
- Such a way a 119
- The breather hose touches the fram 119
- The frame structural and cosmetic damag 119
- The motorcycle can occur 119
- When inspecting the battery be sure the breather hos 119
- Brake light switch adjustment spark plug inspection 120
- Headlight buld replacement 121
- Chapter 3 engine overhaul 123
- Engine removal 125
- Overhaul 125
- Removal 126
- Removal 127
- Engine removal 128
- Engine removal 130
- Removal 131
- Engine disassembly 132
- Disassembly 133
- Cylinde 134
- Disassembly 136
- Thermostati 137
- Water pum 137
- Engine disassembly 138
- Engine disassembly 139
- Engine disassembly 140
- Disassembly 141
- Inspection and repair 143
- A n d repair 145
- Inspectio 145
- Inspectio n and repair 146
- Inspectio n and repair 147
- Inspection and repair 148
- Inspection and repair 149
- Minimum free length outer 149
- Mrn 1 31 in inner 37 5 mm 1 74 in 149
- Relapping steps 149
- Valve spring 149
- Lifter 150
- C a m s h a ft c a m c h a in 151
- Inspectio n and repair 151
- Vu 33210 151
- Inspection and repair 152
- Inspectio n and repair 153
- Inspectio n and repair 155
- Inspection and repair 156
- Inspection and repair 157
- Inspection and repair 158
- Inspection and repair 159
- Minimu 159
- Clearance limit 160
- Crankshaft crankshaft 160
- Crankshaft main bearing clearance measurement 160
- Inspection and repair 160
- Oil galler 160
- Runout limit 160
- Bolts crankcase 161
- Inspection and repair 161
- Main bearingoil clearance 161
- Tighten to full torque in torque sequenc 161
- Inspectio 162
- Inspection and repair 163
- Inspectio n and repair 164
- Bearing co lo r co de 166
- If the crankcase j5 and left balancer shaft sizes are no 4 and no 1 respectively the 166
- Inspectio n and repair 166
- Lower crankcase half is num bered j5 and 166
- O n the gear and shift cam contact sur 166
- Sizes are stam ped on the rh balancer web corner starting with the left journal 166
- Inspectio 167
- Repair 167
- Runout 167
- Unsmoot 167
- Middle gear service 168
- Middle gear service 169
- Middle gear servic 170
- M iddle g ear service 171
- Middle gear service 173
- Middle gear service 174
- Middle gear service 175
- Middle gear service 176
- Middle gear service 177
- Middle gear service 178
- Slowly 178
- Engine assembly and adjustment 179
- Engine assembly and adjustment 180
- Transmission 181
- And adjustment 183
- Engine assembl 183
- Engine assembly and adjustment 184
- Engine assembly and adjustmen 186
- Breather cover 189
- Breather cover spacer 189
- Engine assembly and adjustment 189
- Filter cover 189
- Install 189
- Install starter motor 189
- On the crankcase 189
- On the filter cover mesh with the slots 189
- Sure that the projections 189
- Thermostat assembly 189
- Engine assembly and adjustment 190
- Clutch and oil pump drive gear 191
- Engine assembly and adjustment 191
- Engine assembly and adjustment 192
- Bolt clutch spring 193
- Crankcase cover right 1 193
- Engine assembly and adjustment 193
- Flywheel and starter idle gear 193
- Oil baffle plate 193
- Engine assembly and adjustment 194
- Engine assembly and adjustment 195
- Cylinder head and camshaft 196
- Engine assembly and adjustment 196
- Engine assembly and adjustment 198
- Engine assembly and adjustment 204
- Engine assembly and adjustment 205
- Chapter 4 cooling system 207
- Coolan 208
- Coolant 208
- Coolin 208
- System 208
- Coolant replacement 209
- Engine and radiator are hot scalding hot fluid and steam may be blown out under pressure which could cause serious injury when the engine has cooled open the radiator cap by the 209
- Lowingprocedur 209
- Not remove the radiator cap whe 209
- Thick rag 209
- Towel over the radiator cap slowly rotate the cap counterclockwise to the detent this procedure allows any residual pressure to escape when the hissing sound has stopped press down on the cap while turning counterclockwise and remov 209
- Co o lant 210
- Corrosio 211
- Distille 211
- Bearing and seal replacement 212
- Disassembly 212
- Thermostatic valve 215
- Assembly 216
- Coolant drain valve 216
- Disassembly 216
- Inspection 216
- Assembly 217
- Cylinder head water jacket 217
- Cylinder head water jacket joint 217
- Inspection 217
- Not remove the water jacket joints unless absolutely essential 217
- Radiator and conduit 217
- Removal 217
- Semble the water jacket joints otherwise the coolant will flow into the crankcase 217
- Sure to drain the coolant before you disa 217
- When overhauling the engine 217
- Radiator and conduit 218
- And conduit 220
- Carburetion 221
- Chapte 221
- Chapter 5 carburetion 221
- Carburetion 222
- Carburetor 222
- Carburetor 223
- Sectio 223
- Carburetor 225
- Carbureto r 226
- Carburetor 227
- Assembly 228
- Carburetor 228
- Reassembling wash all parts in clean 228
- Use a new gasket gasoline 228
- Carburetor 229
- Carburetor 230
- Fuel level 230
- Fuel level adjustment steps 230
- Fuel level measurementsteps 230
- In below the carburetor piston valve center 230
- Throttle cable cylinder 231
- Throttle cable cylinder 232
- Throttle cable cylinder 233
- V boost 234
- Air cleaner and crankcase ventilation system 237
- Chapte 238
- Chapter 6 chassis 238
- Chassis 238
- Chassis 240
- Front wheel 240
- Adjust 242
- Limits 242
- Rear wheel 245
- Front and rear brake 248
- Front and rear brake 249
- Front and rear brake 250
- Front and rear brake 251
- Rear brake 252
- Fro nt and rear brake 253
- Front and rear brake 254
- Fro nt and rear brake 256
- Front and rear brake 257
- Front and rear brake 258
- Front and rear brake 259
- Hydraulic clutch 260
- Clutch release disassembly 261
- Hydraulic clutch 261
- Master cylinder disassembly 261
- Hydraulic clutch 262
- Hydraulic clutch 263
- Hydraulic clutch 264
- Hydraulic clutch 265
- Front fork 266
- Front fork 267
- Frontfork 268
- Fro nt fo rk 269
- Frontfork 270
- Steering head 274
- Brake hose joint 276
- It m ay not fall down 276
- Lock washer ring nut 276
- Rem ove nut steering crown 276
- Ring nut lower 276
- Steering head 276
- Suppor 276
- Under bracket so tha 276
- Install 277
- Steerin 278
- Absorber 279
- Rear shock absorber 279
- Rear shock absorber 280
- Absorber 281
- Swingarm 282
- Shaftdrive 286
- Adjust 292
- By the following adjustm ent steps 292
- By the following chart 292
- Dust cover 292
- G ear lash 292
- R em ove bearing housing 292
- R em ove bearing housing with ring gear 292
- Refer to g ear lash adjustm ent section 292
- Ring gear 292
- Select the suitable shim s and thrust 292
- Shaft drive 292
- Shim s 292
- Thrust washer 292
- Washer 292
- B c d e f 297
- Shaft drive 297
- Thrust 300
- Chapte 302
- Chapter 7 electrical 302
- Circuit diagram 304
- Electrical 304
- Circuit diagram 305
- Electrical component 306
- Electrical components 306
- Electrical component 307
- Electrical components 307
- Electrical starting system 308
- Electric starting system 309
- C heck the battery voltage 310
- Connect the lan lead from the starter 310
- Electric starting system 310
- On the 310
- Tro ublesho o ting 310
- Electric starting syste 311
- Sw itc 311
- Electric starting system 312
- Electric starting system 313
- Starter motor test 313
- Electric starting system 314
- Electric startin 315
- System 315
- Electric starting system 318
- Electric starting system 319
- Charging system 320
- System 320
- Chargin 321
- System 321
- Charg ing system 322
- Chargin 323
- System 323
- C 68 f 324
- Chargin 324
- Rectifier test 324
- System 324
- Ignition system 326
- Ignition system 327
- Ignitio 328
- System 328
- System 329
- Ignitio 330
- System 330
- Ignition coil resistance test 331
- Ignition spark gap test 331
- Ignition system 331
- Minimum spark gap 331
- Mm 0 4 in 331
- Primary coil resistance 331
- Secondary coil resistance 13 331
- Spark plug cap 331
- Ignitio 333
- System 333
- Lighting system 334
- Lightin 335
- System 335
- Lightin 336
- System 336
- Check start switch if necessary 337
- Headlight troubleshooting 337
- Lig hting system 337
- Or poor co 337
- Poor ground or poor connection of head light wiring 337
- Signal system 340
- System 340
- System 341
- Battery 342
- Checks 342
- Indicator light 342
- Neutra 342
- Signal system tests an 342
- System 342
- Infinity 343
- System 344
- System 345
- System 347
- Cooling system 348
- System 348
- Coolin 349
- System 349
- Or more 350
- The electric fan will not turn at coolant temperatures o 350
- Troubleshooting 350
- Co o ling system 351
- Coolin 353
- System 353
- Fuel pump system 354
- Aforementioned circuit diagra 355
- For the encircled numbers and color codes 355
- Fuel pump circuit in wiring diagram 355
- Fuel pump system 355
- Fuel pump does not stop afte 359
- Fuel pump system 359
- Indicater light 359
- Onwhile engine isrunning 359
- Seconds whe 359
- Troubleshooting char 359
- Fuel pump system 360
- Fuel pum 361
- System 361
- V boost system 362
- Aforementioned circuit diagram show 363
- Circuit in wiring diagram 363
- For the encircled numbers and color codes see pag 363
- System 364
- At 6 000 r m in 365
- O peration 365
- There is a lag in tim e between the starting of the servo m otor and the opening of the butterfly valves this lag is caused by a slack provided with the control cam e therefore the servo m otor starts to operate at 365
- V bo o st system 365
- Troubleshooting 367
- V bo o st system 368
- Appendices 370
- Chapte 370
- Chapter 8 appendices 370
- Appendices 371
- Specifications 371
- Specifications 377
- Fications 378
- Tightening torque 380
- Specifications 384
- Tightenin 384
- Torque 384
- Specifications 387
- Blies are included in the applicable sections of this book to avoid 388
- Crisscross fashion in progressiv 388
- Definition of units 388
- Fastener assemblies i 388
- For clean dry threads components should b 388
- General torque 388
- General torque specifications 388
- Pitch threads torque specifications for special components or asse 388
- Reached unless otherwise specified torque specifications 388
- Room temperature 388
- Stages 388
- This chart specifies torque for standard fasteners with standard 388
- Tighten 388
- Until full torqu 388
- Conversio 389
- Conversion tables 389
- Tables 389
- Lubrication diagrams 390
- Cable routing 394
- Routing 395
- Routing 396
- Routing 397
- Routing 399
- Routing 400
- Caniste 401
- Routing 401
- Consume 402
- Consumer in 402
- Consumer information 402
- Formation 402
- Wiring diagram 403
- Authentic not artificia 404
- Yamaha 404
- And accessories 405
- Genuin 405
- Protect your investment 405
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