https://ia800204.us.archive.org/14/...ice-manual/yamahavmaxvmx12-service-manual.pdf
Note: updated 5-30-2024
This is a fast download (the above link), but I suggest you save the entire .pdf file on the computer for future reference.
I used to use the vmoa.net location for its .pdf of the factory shop manual, but it seems that the vmoa.net has not been kept available. Here is another source, every '85-'07 owner should save this for future reference.
405 pp. of 'how the factory does it.' If you're new to this publication, check out the layout. The first ~64 pp. are annual updates as the VMax was changed over the years. The VMX12(place a letter suffix here) is specific to a particular model year. That's what you see where changes in the parts and servicing are documented.
Suffixes:
N: 1985
S: 1986
1987 USA none
U:1988
W:1989
A:1990
B: 1991
D: 1992
E: 1993
F: 1994
G: 1995
H: 1996
J: 1997
K: 1998
L: 1999
M: 2000
N: 2001
P: 2002
R: 2003
S: 2004
T: 2005
V: 2006
W1: 2007 yes an additional number, after the letter, and for California, it reads W1C
California models, add the letter 'C' after the yearly letter. They had an evaporative fuel containment system not used on 49-state motorcycles.
Just a quick reminder:
1985: the first year, differences in the exhaust from all other years, also the VBoost I.D.
1986: new design exhaust to comply with USA regulations, VBoost was changed to keep power output the same, with the slightly more-restrictive exhaust. Last year for the 1985-style F & R wheels. The front is cast spokes, the rear is a solid disc wheel with rectangular holes between the hub & the rim.
1987: no USA '1987' models, as unsold inventory from prior two years was sufficient to meet the USA market needs.
1988: USA models resume production.
1989: last year of the two-pickup coil ignition/'old' CDI ignition box
1990: first year of the single-pickup coil ignition/'new' CDI ignition box
1992: last year of the 40mm fork downtubes/sliders, triple trees, and single-opposed piston front disc brakes/smaller front brake rotors
1993: first year of the 43mm fork downtubes/sliders, triple trees, and double opposed piston (four pistons in each caliper) front calipers, and larger front brake rotors
1996: spin-on oil filter (no aluminum enclosure). The frame brace by the oil filter changed to incorporate the spin-on oil filter.
2001: four-pole starter (an easy upgrade, makes starting easier)
There are some other changes of significance, like upgrading the shift selector 'star' segment, and different connecting rods. Anyone who wishes to add that information, please do, and I'll add it to the list.
The 'old-style' 1985-'89 two-pickup coil part #3:
The 'easy I.D.' is to look for five wires at the connector.
The 'new-style' single pickup coil part #3 (1990-2007) The 'easy I.D.' is to look for two wires at the connector.
Thanks to Sean Morley for a pic of different rods over the years.
SpecOps13 (Dave) isn't on here much anymore, but he started a thread with differences by years. Here is his first post, and a link to the thread:
https://www.vmaxforum.net/threads/vmax-parts-compatibility-list-by-year.17148/
Some changes are made to help make it easy to understand, Dave deserves credit for taking the initiative at first. I suspect he consulted Lvlhead's website to get started.
The following is a work in progress. I started this several months ago and asked for your help. I've researched this as far as I can using various and factory parts lists. I need your help again. This will be modified if/when necessary, changed as needed and eventually will provide a reliable guide to the interchangeability of parts for all years of the Gen I VMax... It's still in the developmental stage right now. So, I'm asking for help to verify and organize this and any information that is pertinent too... Any replies you give will go at the end of this thread. I will incorporate your thoughts or info into this first post when confirmed/verified. That way the important part of this thread will be very easy to find, right at the front. For now, it's still mainly my questions of how to organize this and what else to include, eventually it will be answers to what can be interchanged from another year VMax to your bike and work.
Thanx for your assistance.
Dave (SpecOps13)
PS: Items in red are uncertain or may still need to be addressed... (ED note: see link (above) for the red passages)
1. Engine
I know the base engine stayed the same but updates / fixes were accomplished throughout the time the VMax was produced. What I'm thinking of doing here is list when those updates were Incorporated from the first 85 through the last 07. Things like shift segment, any clutch assy updates, gear changes, the plumbing for the dreaded o-ring and so on.
A. Second Gear changed to stronger design in some point of '85. - Note 2nd gear and 5th gear will need to be upgraded together if you discover you have the early design. Shimming was also added to take out slop from the transmission gears.
B. Exhaust, 1985 didn't meet DOT standards, changed in 1986. Exhaust outlet ID was 1mm larger in OD in '85.
C. modest flywheel change 1990. The 85-89 VMax's and Ventures are interchangeable. The 90-07 VMax flywheels are interchangeable and some years venture (though the year they started escapes me). The Venture flywheels are heavier, have more magnet surface, and will run smoother but slow down engine response. (ED. note: notice that the early ignition box and pickup coils correspond to the difference in flywheels, i.e., 1985-1989 (early model) and 1990-2007 (late model). There were minor changes in the ignition harness to accommodate the differences, so again, 1985-'89 early wire harness, vs. 1990-2007 late wire harness. Read-on for other wire harness differences. The early pickup coil and/or flywheel will not work with the late model pickup coil style or late model flywheel, or the late model wire harness. For clarity, what Dave is calling the 'flywheel' is part #2 in each of the fiche Yamaha diagrams (above). The Yamaha fiche calls it the 'rotor assembly' whether it's for the early design ('85-'89) or the late design ('90-'07).
The Starter Clutch is upgradeable with the newer Venture Starter Clutch but not a super cheap or simple swap for the average home mechanic to perform
D. Shift segment upgraded in 99. Heres a how to: http://www.vmaxforum.net/showthread.php?t=10938
This update can be added to any of the previous years and only requires the clutch removal (no engine removal).
E. Dreaded O-Ring fix by factory, in 1999, I now believe to be true.. 2003 was the year that I'd found listed previously but I now have some new evidence that supports 1999 as the year the factory upgraded the Supply Pipe / O-Ring fix. - I have seen o-rings dislodged on virtually all year O-Rings (including a 2006 we worked on). The best preventative is to properly warm up the engine prior to running it hard. A HD oiling system or good sturdy o-ring should be considered.
F. Canister oil filter 1985 thru 1995, block redesigned, stronger, spin on oil filter 1996 and newer also new connecting rods in engine. minor engine redesign 2003. The spin on block does have more internal webbing and great for really big bore motors that are going to see a lot of stress. However, the early blocks still work fine. Don't lose the spring or washer that is located under the filter when performing an oil change. I have a video out here that shows what to look for.
2. Cooling
A. Radiator Cap, changed in 2001 from 10.7-14.9 psi relief pressure to 10.9-15.2 psi relief pressure.
Were there other updates done to any of the cooling system over the years, radiator, fan, thermostat, temp switch,
hoses????
3. Carburetor
A. Main Jets, 1985-86 2 front carbs came with #152.5 main jets, rear 2 carbs came with #150 main jets. 1988 and on came with all carbs using #152.5 main jets. All European models came with all carbs utilizing #150 main jets...
B. Jet Needles. US 49 State models from 1985-95 used 5EZ43, 96 and on used 5EZ43-1
California Models 1985-95 used 5EZ50 and 96 on used 5ez50-1
96 on Euro models used 5EZ19-3..
Most countries besides the U.S. used adjustable needles in the stock carb setup.
C. Pilot Jet, US and California used #37.5 all years.
European Models 96 on used #42.5
D. Pilot Air Jet 1, All 49 State US Models used #90
Cali models used #100
Euro Models from 1996 on used #95
E. Carbs can be interchanged between model years but the inside diameter, jets, needles Throttle Valves and Etc, did have some small differences not shown here. See Service manual Air/Fuel Section, Fuel System Specifications Table for the differences.
F. VBoost tubes were 30 mm ID in '85 and went to 32 mm in 1986 and stayed there.
Note: updated 5-30-2024
This is a fast download (the above link), but I suggest you save the entire .pdf file on the computer for future reference.
I used to use the vmoa.net location for its .pdf of the factory shop manual, but it seems that the vmoa.net has not been kept available. Here is another source, every '85-'07 owner should save this for future reference.
405 pp. of 'how the factory does it.' If you're new to this publication, check out the layout. The first ~64 pp. are annual updates as the VMax was changed over the years. The VMX12(place a letter suffix here) is specific to a particular model year. That's what you see where changes in the parts and servicing are documented.
Suffixes:
N: 1985
S: 1986
1987 USA none
U:1988
W:1989
A:1990
B: 1991
D: 1992
E: 1993
F: 1994
G: 1995
H: 1996
J: 1997
K: 1998
L: 1999
M: 2000
N: 2001
P: 2002
R: 2003
S: 2004
T: 2005
V: 2006
W1: 2007 yes an additional number, after the letter, and for California, it reads W1C
California models, add the letter 'C' after the yearly letter. They had an evaporative fuel containment system not used on 49-state motorcycles.
Just a quick reminder:
1985: the first year, differences in the exhaust from all other years, also the VBoost I.D.
1986: new design exhaust to comply with USA regulations, VBoost was changed to keep power output the same, with the slightly more-restrictive exhaust. Last year for the 1985-style F & R wheels. The front is cast spokes, the rear is a solid disc wheel with rectangular holes between the hub & the rim.
1987: no USA '1987' models, as unsold inventory from prior two years was sufficient to meet the USA market needs.
1988: USA models resume production.
1989: last year of the two-pickup coil ignition/'old' CDI ignition box
1990: first year of the single-pickup coil ignition/'new' CDI ignition box
1992: last year of the 40mm fork downtubes/sliders, triple trees, and single-opposed piston front disc brakes/smaller front brake rotors
1993: first year of the 43mm fork downtubes/sliders, triple trees, and double opposed piston (four pistons in each caliper) front calipers, and larger front brake rotors
1996: spin-on oil filter (no aluminum enclosure). The frame brace by the oil filter changed to incorporate the spin-on oil filter.
2001: four-pole starter (an easy upgrade, makes starting easier)
There are some other changes of significance, like upgrading the shift selector 'star' segment, and different connecting rods. Anyone who wishes to add that information, please do, and I'll add it to the list.
The 'old-style' 1985-'89 two-pickup coil part #3:
The 'easy I.D.' is to look for five wires at the connector.
The 'new-style' single pickup coil part #3 (1990-2007) The 'easy I.D.' is to look for two wires at the connector.
Thanks to Sean Morley for a pic of different rods over the years.
SpecOps13 (Dave) isn't on here much anymore, but he started a thread with differences by years. Here is his first post, and a link to the thread:
https://www.vmaxforum.net/threads/vmax-parts-compatibility-list-by-year.17148/
Some changes are made to help make it easy to understand, Dave deserves credit for taking the initiative at first. I suspect he consulted Lvlhead's website to get started.
The following is a work in progress. I started this several months ago and asked for your help. I've researched this as far as I can using various and factory parts lists. I need your help again. This will be modified if/when necessary, changed as needed and eventually will provide a reliable guide to the interchangeability of parts for all years of the Gen I VMax... It's still in the developmental stage right now. So, I'm asking for help to verify and organize this and any information that is pertinent too... Any replies you give will go at the end of this thread. I will incorporate your thoughts or info into this first post when confirmed/verified. That way the important part of this thread will be very easy to find, right at the front. For now, it's still mainly my questions of how to organize this and what else to include, eventually it will be answers to what can be interchanged from another year VMax to your bike and work.
Thanx for your assistance.
Dave (SpecOps13)
PS: Items in red are uncertain or may still need to be addressed... (ED note: see link (above) for the red passages)
1. Engine
I know the base engine stayed the same but updates / fixes were accomplished throughout the time the VMax was produced. What I'm thinking of doing here is list when those updates were Incorporated from the first 85 through the last 07. Things like shift segment, any clutch assy updates, gear changes, the plumbing for the dreaded o-ring and so on.
A. Second Gear changed to stronger design in some point of '85. - Note 2nd gear and 5th gear will need to be upgraded together if you discover you have the early design. Shimming was also added to take out slop from the transmission gears.
B. Exhaust, 1985 didn't meet DOT standards, changed in 1986. Exhaust outlet ID was 1mm larger in OD in '85.
C. modest flywheel change 1990. The 85-89 VMax's and Ventures are interchangeable. The 90-07 VMax flywheels are interchangeable and some years venture (though the year they started escapes me). The Venture flywheels are heavier, have more magnet surface, and will run smoother but slow down engine response. (ED. note: notice that the early ignition box and pickup coils correspond to the difference in flywheels, i.e., 1985-1989 (early model) and 1990-2007 (late model). There were minor changes in the ignition harness to accommodate the differences, so again, 1985-'89 early wire harness, vs. 1990-2007 late wire harness. Read-on for other wire harness differences. The early pickup coil and/or flywheel will not work with the late model pickup coil style or late model flywheel, or the late model wire harness. For clarity, what Dave is calling the 'flywheel' is part #2 in each of the fiche Yamaha diagrams (above). The Yamaha fiche calls it the 'rotor assembly' whether it's for the early design ('85-'89) or the late design ('90-'07).
The Starter Clutch is upgradeable with the newer Venture Starter Clutch but not a super cheap or simple swap for the average home mechanic to perform
D. Shift segment upgraded in 99. Heres a how to: http://www.vmaxforum.net/showthread.php?t=10938
This update can be added to any of the previous years and only requires the clutch removal (no engine removal).
E. Dreaded O-Ring fix by factory, in 1999, I now believe to be true.. 2003 was the year that I'd found listed previously but I now have some new evidence that supports 1999 as the year the factory upgraded the Supply Pipe / O-Ring fix. - I have seen o-rings dislodged on virtually all year O-Rings (including a 2006 we worked on). The best preventative is to properly warm up the engine prior to running it hard. A HD oiling system or good sturdy o-ring should be considered.
F. Canister oil filter 1985 thru 1995, block redesigned, stronger, spin on oil filter 1996 and newer also new connecting rods in engine. minor engine redesign 2003. The spin on block does have more internal webbing and great for really big bore motors that are going to see a lot of stress. However, the early blocks still work fine. Don't lose the spring or washer that is located under the filter when performing an oil change. I have a video out here that shows what to look for.
2. Cooling
A. Radiator Cap, changed in 2001 from 10.7-14.9 psi relief pressure to 10.9-15.2 psi relief pressure.
Were there other updates done to any of the cooling system over the years, radiator, fan, thermostat, temp switch,
hoses????
3. Carburetor
A. Main Jets, 1985-86 2 front carbs came with #152.5 main jets, rear 2 carbs came with #150 main jets. 1988 and on came with all carbs using #152.5 main jets. All European models came with all carbs utilizing #150 main jets...
B. Jet Needles. US 49 State models from 1985-95 used 5EZ43, 96 and on used 5EZ43-1
California Models 1985-95 used 5EZ50 and 96 on used 5ez50-1
96 on Euro models used 5EZ19-3..
Most countries besides the U.S. used adjustable needles in the stock carb setup.
C. Pilot Jet, US and California used #37.5 all years.
European Models 96 on used #42.5
D. Pilot Air Jet 1, All 49 State US Models used #90
Cali models used #100
Euro Models from 1996 on used #95
E. Carbs can be interchanged between model years but the inside diameter, jets, needles Throttle Valves and Etc, did have some small differences not shown here. See Service manual Air/Fuel Section, Fuel System Specifications Table for the differences.
F. VBoost tubes were 30 mm ID in '85 and went to 32 mm in 1986 and stayed there.
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