vmx VMAX 1200 1996

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FOREWORDThis Supplementary Service Manual has been prepared to introduce new service and data for theVMX12 96. For complete service information procedures it is necessary to use this Supplementary

Service Manual together with the following manual.

VMX12 86 SERVICE MANUAL: 2EN-ME1VMX12 91 SUPPLEMENTARY SERVICE MANUAL: 2EN-AE1VMX12 93 SUPPLEMENTARY SERVICE MANUAL: 2EN-AE2

VMX12 96SUPPLEMENTARYSERVICE MANUAL

1995 by Yamaha Motor Co. Ltd.1st Edition, July 1995

All rights reserved.Any reprinting or unauthorized usewithout the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

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NOTE:

CAUTION:

NOTICEThis manual was written by the Yamaha Motor Company Ltd. primarily for use by Yamaha dealers andqualified mechanics. It is not possible to put an entire mechanics education into one manual, so per-

sons using this book to perform maintenance and repairs on Yamaha motorcycles should have a basicunderstanding of the mechanical concepts and procedures inherent in motorcycle repair technology.Without such knowledge, attempted repairs or service to the motorcycle may render it unfit to useand/or unsafe.

For USA, CaliforniaThis model has been designed and manufactured to perform within certain specifications in regardto performance and emissions. Proper service with the correct tools in necessary to ensure that themotorcycle will operate as designed. If there is any question about a service procedure, it is impera-tive that you contact a Yamaha dealer for any service information changes that apply to this model.This policy is intended to provide the customer with the most satisfaction from his motorcycle and toconform with federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.Modifications and significant changes in specifications or procedures will be forwarded to all Autho-rized Yamaha dealers and will, where applicable, appear in future editions of this manual.

For USA, California:This Service Manual contains information regarding periodic maintenance to the emission control sys-tem. Please read this material carefully.

PARTICULARY IMPORTANT INFORMATIONThis material is distinguished by the following notation.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander, or a person inspecting or repairing themotorcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

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HOW TO USE THIS MANUALCONSTRUCTION OF THIS MANUALThis manual consists of chapters for the main categories of subjects. (See Illustrated symbols)

1st title 1 : This is a chapter with its symbol on the upper right of each page.

2nd title 2 : This title appears on the upper of each page on the left of the chapter symbol. (For thechapter Periodic inspection and adjustment the 3rd title appears.)

3rd title 3 : This is a final title.

MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informationhas been compiled to provide the mechanic with an easy to read, handy reference that contains com-

prehensive explanations of all disassembly, repair, assembly, and inspections.A set of particularly important procedure 4 is placed between a line of asterisks with each proce-dure preceded by F.

IMPORTANT FEATURESSData and a special tool are framed in a box preceded by a relevant symbol 5 .SAn encircled numeral 6 indicates a part name, and an encircled alphabetical letter date or an align-ment mark 7 , the others being indicated by an alphabetical letter in a box 8 .SA condition of a faulty component will precede an arrow symbol and the course of action required 9 .

EXPLODED DIAGRAMEach chapter provides exploded diagrams before each disassembly section for ease in identifying cor-

rect disassembly and assembly procedures.

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15 16

10

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18 19

21 22

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EB003000

ILLUSTRATED SYMBOLSIllustrated symbols 1 to 9 are printed on topright of each page and indicate the subject ofeach chapter.

1 General information

2 Specifications

3 Periodic inspections and adjustments

4 Engine

5 Cooling system

6 Carburetion

7 Chassis

8 Electrical

9 Troubleshooting

Illustrated symbols 10 to 16 are used to identifythe specifications appearing in the text.

10 Filling fluid11 Lubricant12 Special tool13 Torque14 Wear limit, clearance

15 Engine speed16 , V, A

Illustrated symbols 17 to 22 in the exploded dia-grams indicate the types of lubricants and lu-brication points.

17 Apply engine oil18 Apply gear oil19 Apply molybdenum disulfide oil20 Apply wheel bearing grease21 Apply lightweight lithium-soap base grease22 Apply molybdenum disulfide grease

Illustrated symbols 23 to 24 in the exploded dia-grams indicate the where to apply locking agent

23 and when to install new parts 24 .23 Apply locking agent (LOCTITE)24 Replace

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MOTORCYCLE IDENTIFICATIONGENINFO

NOTE:

NOTE:

NOTE:

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONVEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stampedinto the right side of the steering pipe.

Starting serial number:JYA2WEE0 TA050101 (USA)JYA2WFC0 TA012101 (California)

The vehicle identification number is used toidentify your motorcycle and may be used toregister your motorcycle with the licensing au-thority in your state.

FRAME SERIAL NUMBERThe frame serial number 1 is stamped into theright side of the steering pipe.

Starting serial number:2EN-042101 (EUR)

The first three digits of these numbers are formodel identifications; the remaining digits arethe unit production number.

ENGINE SERIAL NUMBERThe engine serial number 1 is stamped into thecrankcase.

Starting serial number:2WE-050101 (USA)2WF-012101 (California)2EN-042101 (EUR)

SThe first three digits of these numbers are formodel identification; the remaining digits arethe unit production number.

SDesigns and specifications are subject tochange without notice.

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SPECIAL TOOLSGENINFO

Oil filter wrenchYU-38411P/N. 90890-01426

This tool is used to remove and install the oilfilter.

Refer to the list provided to avoid errors whenplacing an order.P/N. YM-jjjjj, YU-jjjjj

YS-jjjjj, YK-jjjjjACC-jjjjj

P/N.90890-jjjjj

For

US, CDN

Except for

US, CDN

SPECIAL TOOLSThe proper special tools are necessary for com-plete and accurate tune-up and assembly. Us-

ing the correct special tool will help preventdamage caused by the use of improper tools orimprovised techniques.The shape and part number used for the specialtool differ by country, so two types are provided.

FOR ENGINE SERVICE

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GENERAL SPECIFICATIONS/MAINTENANCE SPECIFICATIONS SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model VMX12

Model code: 3JPM (USA)3JPN (California)3LRA (EUR)

Engine starting number: 2WE-050101 (USA)2WF-012101 (California)2EN-042101 (EUR)

Vehicle identification number: JYA2WEE0 TA050101 (USA)JYA2WFC0 TA012101 (California)

Frame staring number: 2EN-042101 (EUR)Basic weight:With oil and full fuel tank 283 kg (624 lb) (USA)

284 kg (626 lb) (California)281 kg (620 lb) (EUR)

MAINTENANCE SPECIFICATIONSENGINE

Model VMX12

Carburetor:

I.D. MarkMain jet (M.J)Main air jet (M.A.J)Jet needle (J.N)

Needle jet (N.J)Pilot jet (P.J)Pilot air jet (P.A.J.1)Pilot screw (P.S)Pilot outlet (P.O)Bypass 1 (B.P.1)

Bypass 2 (B.P.2)Bypass 3 (B.P.3)Valve seat size (V.S)Starter jet (G.S.1)Starter jet (G.S.2)Throttle valve size (Th.V)Fuel level (F.L)Engine idling speed

Vacuum pressure at idling speed

1FK 02 (USA), 2WF 02 (California), 3LR 01 (EUR)#152.5 (USA, California), #150 (EUR)2.05EZ43-1 (USA), 5EZ50-1 (California),5EZ19-3 (EUR)Y-0#37.5 (USA, California), #42.5 (EUR)#90 (USA), #100 (California), #95 (EUR)2-1/4 (USA), 3 (California), 2-1/2 (EUR)0.90.8

0.80.91.5#45#0.8#125 (USA, EUR), #130 (California)15X 17 mm (0.59X 0.66 in)950X 1,050 r/min (USA, EUR),1,050X 1,150 r/min (California)26.7 kPa (200 mmHg, 7.87 in Hg) (USA, EUR),33.3 kPa (250 mmHg, 9.84 in Hg) (California)

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MAINTENANCE SPECIFICATIONS SPEC

ELECTRICAL

Model VMX12

Rectifier:Model/manufacturerCapacityWithstand Voltage

SH662-12/SHINDENGEN25 A200 V

Electric starter system:TypeStarter motor:Model/manufacturerOutputBrush overall length

Commutator diameterMica undercut

Starter switch:Model/manufacturerAmperage ratingCoil winding resistance

Constant mesh type

SM-13/MITSUBA0.65 kW12.5 mm (0.49 in)

28 mm (1.10 in)0.7 mm (0.03 in)

MS5D-191/HITACHI100 A3.9X 4.7 at 20_C (68_F)

Thermostatic switch:Model/manufacturer 2EL (USA), 47X (California, EUR)/

NIHON THERMOSTAT

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ENGINE OIL REPLACEMENTINSPADJ

NOTE:

PERIODIC INSPECTION ANDADJUSTMENT

ENGINEENGINE OIL REPLACEMENT1. Start the engine and let it warm up for several

minutes.2. Stop the engine and place an oil pan under

the drain bolt.

3. Remove:SOil filler cap 1

4. Remove:SDrain bolt 1 (with gasket)Drain the crankcase of its oil.

5. If the oil filter is to be replaced during this oil

change, remove the following parts and rein-stall them.

Replacement steps:FRemove the oil filter 1 using the oil filter

wrench 2 .

Oil filter wrench:YU-38411, 90890-01426

FApply engine oil to the O-ring 3 of the new oilfilter.

Make sure the O-ring 3 is positioned correctly.

FTighten the oil filter using the oil filter wrench.

Oil filter:

18 Nm (1.8 mSkg, 13 ftSlb)

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ENGINE OIL REPLACEMENTINSPADJ

NOTE:

NOTE:

CAUTION:

6. Install:SDrain bolt

Drain bolt:43 Nm (4.3 mSkg, 31 ftSlb)

Always use a new gasket.

7. Fill:SCrankcase

Recommended oil:

At 5_C (40_F) or higher A :SAE 20W40 type SE motor oil

At 15_C (60_F) or lower B :SAE 10W30 type SE motor oil

Oil quantity:Total amount:

4.7 L (4.1 lmp qt, 5.0 US qt)Periodic oil change:

3.5 L (3.1 lmp qt, 3.7 US qt)With oil filter replacement:

3.8 L (3.3 lmp qt, 4.0 US qt)

Recommended oil classification: API ServiceSE, SF and SG type or equivalent (e.g.SF-SE, SF-SE-CC, SF-SE-SD etc.).

SDo not add any chemical additives.Engine oil also lubricates the clutch andadditives could cause clutch slippage.

SDo not allow foreign material to enter the

crankcase.

8. Install:SOil filler cap

9. Warm up the engine for a few minutes, thenstop the engine.

10. Inspect:S

Engine (for oil leaks)SOil level

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INSPECTION AND REPAIR ENG

CAUTION:

NOTE:

ENGINE OVERHAUL

INSPECTION AND REPAIRCRANKSHAFT AND CONNECTING ROD1. Measure:SRunout (crankshaft)Out of specification! Replace.

Runout:Less than 0.03 mm (0.0012 in)

2. Inspect:SMain journal surfacesSCrank pin surfacesSBearing surfacesWear/Scratches! Replace.

3. Measure:SOil clearance (main journal)Out of specification! Replace bearing.

Oil clearance:0.020X 0.038 mm(0.0008X 0.0015 in)

Measurement steps:

Do not interchange the bearings and con-

necting rod. They must be installed in theiroriginal positions, or the correct oil clear-ance may not be obtained causing enginedamage.

FClean the bearings, main journals and bear-ing portions of the crankcase.

FPlace the crankcase (upper) on a bench in anupside down position.

F Install the upper half of the bearings and thecrankshaft into the crankcase (upper).

Align the projection of the bearing with the notchin the crankcase.

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NOTE:

NOTE:

CAUTION:

FPut a piece of Plastigauge on each mainjournal.

Do not put the Plastigauge over the oil hole inthe main journal of the crankshaft.

F Install the lower half of the bearings into thecrankcase (lower) and assemble the crank-case halves.

SAlign the projection of the bearing with thenotch in the crankcase.SDo not move the crankshaft until the oil clear-ance has been completed.

FTighten the bolts to specification in the tight-ening sequence cast on the crankcase.

Bolt (Crankcase-M10):40 Nm (4.0 mSkg, 29 ftSlb)

*With a washerFRemove the crankcase (lower) and lower half

of the bearing.

FMeasure the compressed Plastigaugewidth a on each main journal.If oil clearance is out of specification, select areplacement bearing.

4. Measure:SOil clearance (crank pin)Out of specification! Replace bearing.

Oil clearance:

0.021X 0.039 mm(0.0008X 0,0015 in)

Measurement steps:

Do not interchange the bearings and con-necting rod. They must be installed in theiroriginal positions, or the correct oil clear-ance may not be obtained causing enginedamage.

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NOTE:

NOTE:

CAUTION:

FClean the bearings, crank pins and bearingportions of the connecting rods.

F Install the upper half of the bearing into the

connecting rod and lower half of the bearinginto the connecting rod cap.

Align the projection of the bearing with the notchof the cap and connecting rod.

FPut a piece of Plastigauge on the crank pin.FAssemble the connecting rod halves.

SDo not move the connecting rod or crankshaft

until the oil clearance measurement has beencompleted.SApply molybdenum disulfide grease to thebolts, threads and nut seats.SMake sure the Y marks on the connectingrods face the left side of the crankshaft.SMake sure that the letters on both componentsalign to from a perfect character.

FTighten the nuts.

Nut:36 Nm (3.6 mSkg, 25 ftSlb)

Tighten to full torque specification withoutpausing. Apply continuous torque between3.0 and 3.8 mSkg. Once you reach 3.0 mSkg,DO NOT STOP TIGHTENING until finaltorque is reached. If tightening is inter-rupted between 3.0 and 3.8 mSkg, loosen nutto less than 3.0 mSkg and start again.

FRemove the connecting rods and bearings.FMeasure the compressed Plastigauge

width a on each crank pin.If oil clearance is out of specification, select areplacement bearing.

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5. Select:SMain journal bearing (J1X J4)SCrank pin bearing (P1X P2)

Selection of bearings:Example 1: Main journal bearingF If J1 on the crankcase is 6 and 1 on the

crankweb, then the bearing size for J1 is:

Bearing size of J1:Crankcase J1 Crankweb J1 =6 1 = 5 (Yellow)

BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

5 Yellow

6 Pink

7 Red

Example 2: Crank pin bearingF If P1 on the connecting rod is 4 and 2 on

the crankweb, then the bearing size for P1is:

Bearing size of P1:

Connecting rod P1 Crankweb P1 =4 2 = 2 (Black)

BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

5 Yellow

6 Pink

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NOTE:

BALANCER SHAFT1. Measure:SOil clearance (balancer shaft bearing)

Out of specification! Replace bearing.

Oil clearance:0.020X 0.048 mm(0.0008X 0.002 in)

Measurement steps:FClean the bearings, balancer shaft and bear-

ing portions of the crankcase.FPlace the crankcase (upper) on a bench in an

upside down position.

F Install the upper half of the bearings and thebalancer shaft into the crankcase (upper).

FPut a piece of Plastigauge on each balanc-er shaft journal.

F Install the lower half of the bearings into thecrankcase (lower) and assemble the crank-case halves.

Do not move the balancer shaft until the oilclearance measurement has been completed.

FTighten the bolts to specification in the tight-ening sequence cast on the crankcase.

Bolt (crankcase-M8):24 Nm (2.4 mSkg, 17 ftSlb)

FRemove the crankcase (lower) and lower halfof the bearings.

FMeasure the compressed Plastigaugewidth a on each balancer shaft journal. If oilclearance is out of specification, select a re-placement bearing.

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2. Select:SBalancer shaft bearing

Selection of bearings:Example:F If J5 on the crankcase is 6 and 2 on the

balancer shaft, then the bearing size for J5is:

Bearing size of J5:Crankcase J5 Balancer shaft No. =6 2 = 4 (Green)

BEARING COLOR CODE

1 Blue

2 Black

3 Brown

4 Green

5 Yellow

6 Pink

7 Red

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MIDDLE GEAR SERVICE ENG

11 Damper spring12 Damper cam

13 Middle drive pinion gear14 Thrust washer15 Retainer



A SHIMS:0.10 mm (0.004 in)

BGEAR LASH:0.05X 0.12 mm(0.002X 0.005 in)

A

SHIMS:0.15 mm (0.006 in)0.30 mm (0.012 in)

0.50 mm (0.020 in) C 110 Nm (11.0 mS

kg, 80 ftS

lb)STAKE

MIDDLE GEAR SERVICE

1 Universal joint2 Dust seal

3 Housing4 O-ring5 Bearing6 Collapsible collar7 Bearing8 Middle drive shaft9 Middle driven pinion gear

10 Spring seat

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SHAFT DRIVE CHAS

14 Bearing15 Bearing16 Drive pinion gear17 Final drive gear shim18 Bearing19 Bearing retainer20 O-ring21 Oil seal22 Coupling gear23 Spring24 Circlip25 Drive shaft26 Oil seal

27 Washer28 Circlip29 Bearing30 Circlip31 Universal joint





110 Nm (11.0 mSkg, 80 ftSlb)

9 Nm (0.9 mSkg, 6.5 ftSlb)

E

SIZES: 4

A FINAL GEAR OIL:

B CAPACITY:0.2 L (0.18 lmp qt, 0.21 US qt)

CTYPE:SAE 80 API GL-4 HYPOID GEAR OIL

D GEAR LASH:0.1X 0.2 mm (0.004X 0.008 in)

E

SIZED: 5E

SIZES: 2

E SIZES: 3

130 Nm(13.0 mSkg, 94 ftSlb)

23 Nm(2.3 mSkg, 17 ftSlb)

CHASSISSHAFT DRIVE1 Dust cover2 Bearing housing3 Ring gear stopper shim4 Ring gear stopper5 O-ring6 Oil seal7 Ring gear shim8 Bearing9 Ring gear

10 Thrust washer11 Bearing12 Oil seal13 Collar

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vmx VMAX 1200 1996