Yamaha VMX12 96 Manual

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
All rights reserved.
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.

23
20
17
15 16
10
12
13
11
14
1
3
5
7
9
2
4
8
6
18 19
21 22
24
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–
E
MOTORCYCLE IDENTIFICATION GEN
INFO
NOTE:
NOTE:
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
register your motorcycle with the licensing au-
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–
E
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