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FOREWORD

This Supplementary Service Manual has been prepared to introduce new service and data for the
VMX12 ’93. 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

1992 by Yamaha Motor Co., Ltd.

1st Edition, November 1992

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Co., Ltd.

is expressly prohibited.

Summary of Contents for VMX12 93

Page 1: ......

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Page 3: ...o 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 1992 by Yamaha Motor Co Ltd 1st Edition November 1992 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...ally 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 PARTICULARLY IMPORTANT INFORMATION This material is distinguished by the following notation The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SA...

Page 5: ...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 IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5 An encircled numeral 6 indicates a part name and an encircle...

Page 6: ... Chassis 8 Electrical 9 Troubleshooting Illustrated symbols 10 to 16 are used to identify the specifications appearing in the text 10 Filling fluid 11 Lubricant 12 Special tool 13 Tightening 14 Wear limit clearance 15 Engine speed 16 Ω V A Illustrated symbols 17 to 24 in the exploded dia gram indicate grade of lubricant and location of lubrication point 17 Apply engine oil 18 Apply gear oil 19 App...

Page 7: ...E SERIAL NUMBER Except for E 1 ENGINE SERIAL NUMBER 1 SPECIAL TOOL 2 FOR CHASSIS SERVICE 2 SPECIFICATIONS 3 GENERAL SPECIFICATIONS 3 MAINTENANCE SPECIFICATIONS 4 ENGINE 4 CHASSIS 4 ELECTRICAL 5 CHASSIS 6 FRONT AND REAR BRAKE 6 FRONT FORK 7 REMOVAL 8 DISASSEMBLY 9 INSPECTION 10 ASSEMBLY 11 INSTALLATION 14 ...

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Page 9: ...FRAME SERIAL NUMBER Except for E The frame serial number 1 is stamped into the right side of steering head Starting serial number 2EN 031101 F I B PRT GB The first three digits of these numbers are for model identifications the remaining digits are the unit production number ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the left side of the engine Starting serial number 2EN 03110...

Page 10: ...ten the front fork damper rod holding bolt Front fork seal driver weight P N YM 33963 P N 90890 01367 Adapter 43 mm P N YM 8020 P N 90890 01374 These tools are used when installing the fork seal 2 1 2 SPECIAL TOOLS The proper special tools are necessary for com 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 im...

Page 11: ... number Frame starting number Vehicle identification number 3LR8 F I B PRT GB 3LR9 E 2EN 031101 F I B PRT GB 2EN 041101 E 2EN 031101 F I B PRT GB JYA2ENS0 PA041101 E Minimum turning radius 2 900 mm 114 in Tire Type Size F Size R Wear limit Tubeless 110 90V 18 METZELER ME33 150 90VB 15 M C METZELER ML2 1 0 mm 0 04 in ...

Page 12: ... free length Limit Collar length Spring rate K1 K2 Stroke K1 K2 Optional spring Oil capacity Oil level Oil grade Enclosed air pressure standard Min Max 140 mm 5 51 in 386 5 mm 15 2 in 381 5 mm 15 0 in 245 mm 9 65 in 3 75 N mm 0 375 kg mm 21 0 lb in 4 90 N mm 0 5 kg mm 28 0 lb in 0 78 mm 0 3 07 in 78 140 mm 3 07 5 51 in No 619 cm3 21 8 lmp oz 20 9 US oz 123 mm 4 8 in Yamaha fork oil 10wt or equival...

Page 13: ... 5 E MAINTENANCE SPECIFICATIONS SPEC ELECTRICAL Model VMX12 T C I Pickup coil resistance color T C I Unit model Manufacturer 81 121 Ω at 20_C 68_F Black Orange BB7224 HITACHI ...

Page 14: ...The arrow mark on the pad spring must point in the disc ro tating direction A FRONT CALIPER B PAD WEAR LIMIT 0 5 mm 0 02 in C D MINIMUM DISC THICKNESS 4 5 mm 0 18 in MAXIMUM DEFLECTION 0 3 mm 0 01 in 35 Nm 3 5 m kg 25 ft lb 20 Nm 2 0 m kg 14 ft lb 20 Nm 2 0 m kg 14 ft lb 35 Nm 3 5 m kg 25 ft lb E PAD SPRING 5 Nm 0 5 m kg 3 6 ft lb CHASSIS FRONT AND REAR BRAKE ...

Page 15: ...z 20 9 US oz C GRADE Yamaha Fork Oil 10wt or equivalent D STD AIR PRESSURE 39 2 kPa 0 4 kg cm2 5 7 psi E MIN TO MAX AIR PRESSURE 39 2 98 1 kPa 0 4 1 0 kg cm2 5 7 14 2 psi F FORK SPRING FREE LENGTH LIMIT 381 5 mm 15 0 in 20 Nm 2 0 m kg 14 ft lb 23 Nm 2 3 m kg 17 ft lb 62 Nm 6 2 m kg 45 ft lb FRONT FORK 9 Outer fork tube 10 Oil lock piece 11 Damper rod 12 Fork spring 13 Spring seat 14 Collar 15 Cap ...

Page 16: ...nd under the engine 3 Remove Caliper assembly 1 Brake hose holder 2 4 Disconnect Speedometer cable 3 Do not depress the brake lever when the wheel is off the motorcycle otherwise the brake pads will be forced shut 5 Loosen Pinch bolt 1 wheel axle 6 Remove Wheel axle 2 Front wheel assembly 7 Remove Front fender 1 Fork brace 2 8 Remove Fork cap 1 Depress the valve 2 until all of the air has been rel...

Page 17: ...e Cap bolt 1 Spacer 2 Spring seat 3 Spring 4 2 Drain Fork oil 3 Remove Dust seal Retaining clip 1 Use a thin slotted head screw driver Take care not to scratch the inner tube 4 Remove Bolt damper rod Copper washer Loosen the bolt damper rod while holding the damper rod with the T handle and holder T handle YM 01326 90890 01326 Holder 29 mm YM 33962 90890 01375 5 Remove Inner fork tube ...

Page 18: ...shes Damage oil seal and bushing must be replaced SAvoid bottoming the inner tube in the outer tube during the above procedure as the oil lock piece will be damaged 6 Remove SOil seal 1 SSeal spacer 2 SSlide metal 3 SPiston metal SDamper rod SOil lock piece INSPECTION 1 Inspect SInner fork tube SOuter fork tube Scratches Bends Damage Replace Do not attempt to straighten a bent inner fork tube as t...

Page 19: ...ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points In front fork reassembly be sure to use follow ing new parts Piston metal Slide metal Oil seal Dust seal Make sure that al components are clean be fore reassembly 1 Install Damper rod Allow the damper rod to slide slowly down the inner fork tube until it protrudes from the bottom being careful not to damage the in ner fork tube ...

Page 20: ...en the bolt damper rod while holding the damper rod with the T handle and holder T handle YM 01326 90890 01326 Holder 29 mm YM 33962 90890 01375 5 Install Slide metal Seal spacer Oil seal 1 Use the fork seal driver weight and adapter Fork seal driver weight YM 33963 90890 01367 Adapter 43 mm YM 8020 90890 01374 Before installing the oil seal apply the lithium soap base grease onto the oil seal lip...

Page 21: ...21 8 lmp oz 20 9 US oz Fork oil 10w or equivalent after filling slowly pump the fork up and down to distribute oil Oil level 123 mm 4 8 in from the top of inner fork tube fully compressed without spring Place the front fork on upright position 9 Install Fork spring 1 Spring seat 2 Spacer collar 3 Cap bolt 4 Fork spring must be installed with the smaller pitch upward Before installing the cap bolt ...

Page 22: ...ch bolts 1 under bracket Cap bolt 2 front fork Pinch bolt 3 handle crown Pinch bolt lower bracket 23 Nm 2 3 m kg 17 ft lb Cap bolt front fork 23 Nm 2 3 m kg 17 ft lb Pinch bolt handle crown 23 Nm 2 3 m kg 17 ft lb 3 Adjust Front fork air pressure Refer to FRONT FORK ADJUSTMENT in the CHAPTER 2 4 Install Fork brace 1 Front fender 2 5 Install Front wheel Front wheel axle 60 Nm 6 0 m kg 43 ft lb Pinc...

Page 23: ... 15 E FRONT FORK CHAS WARNING 6 Install Caliper assembly 1 Brake hose holder 2 Speedometer cable 3 Bolt caliper bracket 35 Nm 3 5 m kg 25 ft lb Make sure that the brake hose are routed properly ...

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