Yamaha VMX12 96 Handbuch

FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the

VMX12 ’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-ME1

VMX12 ’91 SUPPLEMENTARY SERVICE MANUAL: 2EN-AE1

VMX12 ’93 SUPPLEMENTARY SERVICE MANUAL: 2EN-AE2

VMX12 ’96

SUPPLEMENTARY

SERVICE MANUAL

1995 by Yamaha Motor Co. Ltd.

1st Edition, July 1995

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

CAUTION:

NOTICE

ThismanualwaswrittenbytheYamahaMotorCompanyLtd.primarilyforusebyYamahadealersand

qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so per-

sonsusingthisbooktoperformmaintenanceandrepairsonYamahamotorcyclesshouldhaveabasic

understanding 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 use

and/or unsafe.

For USA, California

Thismodelhasbeendesignedand manufactured to performwithincertainspecificationsinregard

toperformanceandemissions.Properservicewiththecorrecttoolsinnecessarytoensurethatthe

motorcyclewilloperateasdesigned.Ifthereisanyquestionaboutaserviceprocedure,itisimpera-

tivethatyoucontact a Yamahadealerfor any service informationchangesthat apply to thismodel.

Thispolicyisintendedtoprovidethecustomerwiththemostsatisfactionfromhismotorcycleandto

conform 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:

ThisServiceManualcontainsinformationregardingperiodicmaintenancetotheemissioncontrolsys-

tem. Please read this material carefully.

PARTICULARY IMPORTANT INFORMATION

This material is distinguished by the following notation.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

SAFETY IS INVOLVED!

FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathto

the motorcycle operator, a bystander, or a person inspecting or repairing the

motorcycle.

ACAUTION indicates specialprecautions that mustbe taken toavoid damage

to the motorcycle.

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

HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL

This 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 the

chapter “Periodic inspection and adjustment” the 3rd title appears.)

3rd title 3: This is a final title.

MANUAL FORMAT

Alloftheproceduresinthismanualareorganizedinasequential,step-by-stepformat.Theinformation

has 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 4is placed between a line of asterisks “ ” with each proce-

dure preceded by “”.

IMPORTANT FEATURES

Data and a special tool are framed in a box preceded by a relevant symbol 5.

Anencirclednumeral 6indicatesapartname,andanencircledalphabeticalletterdateoranalign-

ment mark 7, the others being indicated by an alphabetical letter in a box 8.

Aconditionofafaultycomponentwillprecedeanarrowsymbolandthecourseofactionrequired 9.

EXPLODED DIAGRAM

Eachchapterprovidesexplodeddiagramsbeforeeachdisassemblysectionforeaseinidentifyingcor-

rect disassembly and assembly procedures.

15 16

18 19

21 22

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1to 9are printed on top

right of each page and indicate the subject of

each chapter.

1General information

2Specifications

3Periodic inspections and adjustments

4Engine

5Cooling system

6Carburetion

7Chassis

8Electrical

9Troubleshooting

Illustrated symbols 10 to 16 are used to identify

the specifications appearing in the text.

10 Filling fluid

11 Lubricant

12 Special tool

13 Torque

14 Wear limit, clearance

15 Engine speed

16 Ω, V, A

Illustratedsymbols 17 to 22 inthe exploded dia-

grams indicate the types of lubricants and lu-

brication points.

17 Apply engine oil

18 Apply gear oil

19 Apply molybdenum disulfide oil

20 Apply wheel bearing grease

21 Apply lightweight lithium-soap base grease

22 Apply molybdenum disulfide grease

Illustratedsymbols 23 to 24 inthe exploded dia-

gramsindicatethewheretoapplylockingagent

23 and when to install new parts 24 .

23 Apply locking agent (LOCTITE)

24 Replace

CONTENTS

GENERAL INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTORCYCLE IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION NUMBER 1. . . . . . . . . . . . . . . . . . . . .

FRAME SERIAL NUMBER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SERIAL NUMBER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC INSPECTION AND ADJUSTMENT 5. . . . . . . . . . . . . . . . . . . .

ENGINE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL REPLACEMENT 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OVERHAUL 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSPECTION AND REPAIR 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKSHAFT AND CONNECTING ROD 7. . . . . . . . . . . . . . . . . .

BALANCER SHAFT 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MIDDLE GEAR SERVICE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHAFT DRIVE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

–1–

MOTORCYCLE IDENTIFICATION GEN

INFO

NOTE:

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

Thevehicleidentificationnumber 1isstamped

into the right side of the steering pipe.

Starting serial number:

JYA2WEE0 TA050101 (USA)

JYA2WFC0 TA012101 (California)

The vehicle identification number is used to

identify your motorcycle and may be used to

thority in your state.

FRAME SERIAL NUMBER

The frame serial number 1is stamped into the

right side of the steering pipe.

Starting serial number:

2EN-042101 (EUR)

The first three digits of these numbers are for

model identifications; the remaining digits are

the unit production number.

ENGINE SERIAL NUMBER

Theengineserialnumber 1isstampedintothe

crankcase.

Starting serial number:

2WE-050101 (USA)

2WF-012101 (California)

2EN-042101 (EUR)

The first three digits of these numbers are for

model identification; the remaining digits are

the unit production number.

Designs and specifications are subject to

change without notice.

–2–

SPECIAL TOOLS GEN

INFO

Oil filter wrench

YU-38411

P/N. 90890-01426

This tool is used to remove and install the oil

filter.

Refer to the list provided to avoid errors when

placing an order.

P/N. YM-jjjjj, YU-jjjjj

YS-jjjjj, YK-jjjjj

ACC-jjjjj

P/N.90890-jjjjj

For

US, CDN

Except for

US, CDN

SPECIAL TOOLS

Theproperspecialtoolsarenecessaryforcom-

plete and accurate tune-up and assembly. Us-

ing the correct special tool will help prevent

damage caused by the use of improper tools or

improvised techniques.

Theshapeandpartnumberusedforthespecial

tooldifferbycountry, so twotypes are provided.

FOR ENGINE SERVICE

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