VMax Parts Compatibility List by Year

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SpecOps13

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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

PS: Items in red are uncertain or may still need to be addressed...


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.


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.


What Else ?

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????

Changes to anything ???

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.


Any other updates / upgrades that were done over the years? I want to include the Vboost Tubes (Mechanical parts) here too..


F. VBoost tubes were 30 mm ID in '85 and went to 32 mm in 1986 and stayed there.

4. Chassis...

Wheels, rotors, calipers, brake master cylinder, front forks, anything that changed and the years that those changes were made.

A. Wheels....

1. 85 had different style rear wheel. It will bolt onto any VMax 85-07..

2. 86 say a new style rear wheel.

3. 85-86 had spoked front wheel, it's lighter than later models. It will bolt onto any VMax 85-07..

Note, From Lvlhead's VMax Page: "In 1987 the VMax was not available in the United States. I?ve heard two different reasons for this. One, it didn?t meet new EPA regulations and two, it?s been said that an over stock of ?86 models resulting from low sales numbers was the cause. The ?87 and ?88 Canadian models came with a chromed instrument cover. (The chrome instrument cover is not available through Yamaha dealers in the United States.)"

4. 88 new style front wheel.

B. Brakes...

1. 85-92 had smaller front rotors, 282 mm, not cross drilled. 2 pot calipers Will bolt onto any VMax but too small to use with 93-07 calipers. The Right Front Rotor from these early years are the same as all years Rear Rotor.


2. 93-2007 larger front rotors, 298 mm, 4 pot calipers. 4 Piston R1/R6/Warrior Calipers all bolt up in place of the stock 4 pots. BUT, be warned the banjo location is different and will make your stock lines run a little weird. You can use -2" shorter lines to get the stock routing back the same. 94/95 FZR750R and 94 FZR1000 6 Piston Calipers are a direct interchange and perfect line mounting location.


C. Front Forks

1. 85-92 had smaller OD fork tubes (40mm) with air crossover tube, left side near top of fork, oil drain screw and matching triple clamps. Entire fork, triple, caliper assembly can be swapped to any year.

2. 93-07 had larger OD fork tubes (43mm)and matching triple clamps, no oil drain screw and no air balance tube, individual air valves at the top of each fork.

3. 01, slight changes fork damper rod and bolt, fork guard added to lower legs.. Fork Guard will not directly fit on earlier forks. The entire fork assembly must be swapped.


D. 96-07 Rear axle. Changed to 1/4" shorter axle. Washers also changed...

E. 96-07 Differential machined to accept shorter axle. Bears a surface to mount speedometer in housing. - this speedo pickup is seen on the Royal Star rear diffs (which bolts on and is 10% lower gear ratio). Would require leaving the pickup unit bolted in place. 86-93 Venture rear diffs are a direct interchange but the shock mount needs to be swapped over (or a new mount purchased and added to the Venture diff)



What Else ???

5. Electrical, Many of electrical changes in 90 due to new digital ignition...

A. ECU, Upgraded to digital electronics 90..... 1985-1989=1FK-82305-09-00, 1990 on 3JP-82305-13-00..

B. VBoost controller, changed in 1993..... 1985-1992=1FK-85830-M2-00 , 1993 on 1FK-85830-M0-00.. - All years interchange.


C. Turn Signal Relay, changed in 1990.... 1985-1989=41R-83350-71-00, 1990 on 2UJ-83350-00-00...

D. Wiring Harness, changed in 90 for digital electronics... 1985-1989= 1UT-82590-01-00 , 1990 on 3JP-82590-00-00....

E. Ignition Coils, 1985-1989=25G-82310-10-00 , the terminals are red/white and either orange, gray, yellow or white. depending on the coil/cylinder number... 1990 on, connectors are red/white and orange on the coil side of each ignition coil. Coil function and testing is the same for both. - All years interchange.


F. Reserve / normal fuel control, Fuel Pump changed in 2003. 1985-2002=1FK-13907-00-00, 2003 on 1FK-13907-01-00.. - All years interchange.


G. ignition Module, changed to digital in 90... 1985-1989= 1FK-82305-10-00 , 1990 on 3JP-82305-11-00....

H. Starter, Starter changed to a 4 pole model in 2001... 1985-2000= 1FK-81800-10-00, 2001 on 1FK-81890-00-00... - All years interchange.


I. Tank cover gauge cluster, changed for digital electronics 1990, 2003 different style script and redline lowered to 9,000. Instrument panel can be swapped as long as the wiring harness is the type originally used on the bike it's being installed on.

J. Speedometer: changed part number often, basic function remained the same, 2003 different style script.. 1985-1991= 3LR-83570-00-00, 1992 1FK-83570-A0-00, 1993= 1FK-83570-A1-00, 2002= 1FK-83570-A2-00, 2003 1FK-83570-B0-00, 2004=3LR-83570-00-00, 2005= 1FK-83570-B0-00, 2006-2007 5GK-83570-00-00...

K. Stator, upgraded for more output 93-07... 1985-1989= 1FK-81410-11-00, 1993 on= 3UF-81410-10-00... 86-93 Venture Stators interchange and have more output.


L. Voltage Rectifier / Regulator. Changed from original, Lower amperage. Changed to a finned model 1998-2007 model is preferred when older model goes bad or is replaced. Need longer bolts for the newer model when swapping out early style regulator.

 
M. Starter Relay: Changed in 1990 to a higher resistance coil. 1985-1989, 36Y-81940-00-00, 1990 on= 3UF-81940-00-00... Wiring completely changed but it is possible to swap with a jumper wire added in on the later years.


N. Diode Assembly / Kickstand Safety Device: Shows the same part number from 1985 thru 2007 for the United States anyway.... 4U8-81980-M0-00,

What Else?

6. Bodywork...

A. side panels VMax pressed into metal 1985. 1986 and newer have a stick on VMax badge..

B. footpegs changed style in 1986..

What Else?
 
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Jack Butler: You are partly right.... Oops:ummm:My Bad but the reason for you viewing this....


Lvlhead's VMax: "In 1987 the Vmax was not available in the United States. I?ve heard two different reasons for this. One, it didn?t meet new EPA regulations and two, it?s been said that an over stock of ?86 models resulting from low sales numbers was the cause. The ?87 and ?88 Canadian models came with a chromed instrument cover. (The chrome instrument cover is not available through Yamaha dealers in the United States.)"
 
Thanx for the Sticky Stuff....:biglaugh: COOL........

I'll do my best to keep it up with anything new that someone finds..
Post it here but always check the first post of this thread for current updates...
 
Jack Butler: You are partly right.... Oops:ummm:My Bad but the reason for you viewing this....


Lvlhead's VMax: "In 1987 the Vmax was not available in the United States. I?ve heard two different reasons for this. One, it didn?t meet new EPA regulations and two, it?s been said that an over stock of ?86 models resulting from low sales numbers was the cause. The ?87 and ?88 Canadian models came with a chromed instrument cover. (The chrome instrument cover is not available through Yamaha dealers in the United States.)"


Nice find...Cheers!
 
PS: Items in red are uncertain or may still need to be addressed...

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.

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 orings (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.

What Else ?

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????

Changes to anything ???

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.


Any other updates / upgrades that were done over the years? I want to include the Vboost Tubes (Mechanical parts) here too..


F. VBoost tubes were 30 mm ID in '85 and went to 32 mm in 1986 and stayed there.

4. Chassis...

Wheels, rotors, calipers, brake master cylinder, front forks, anything that changed and the years that those changes were made.

A. Wheels....

1. 85 had different style rear wheel. It will bolt onto any VMax 85-07..

2. 86 say a new style rear wheel.

3. 85-86 had spoked front wheel, it's lighter than later models. It will bolt onto any vmax 85-07..

Note, From Lvlhead's VMax Page: "In 1987 the Vmax was not available in the United States. I?ve heard two different reasons for this. One, it didn?t meet new EPA regulations and two, it?s been said that an over stock of ?86 models resulting from low sales numbers was the cause. The ?87 and ?88 Canadian models came with a chromed instrument cover. (The chrome instrument cover is not available through Yamaha dealers in the United States.)"

4. 88 new style front wheel.

B. Brakes...

1. 85-92 had smaller front rotors, 282 mm, not cross drilled. 2 pot calipers Will bolt onto any vmax but too small to use with 93-07 calipers. The Right Front Rotor from these early years are the same as all years Rear Rotor.

2. 93-2007 larger front rotors, 298 mm, 4 pot calipers. 4 Piston R1/R6/Warrior Calipers all bolt up in place of the stock 4 pots. BUT, be warned the banjo location is different and will make your stock lines run a little weird. You can use -2" shorter lines to get the stock routing back the same. 94/95 FZR750R and 94 FZR1000 6 Piston Calipers are a direct interchange and pefect line mounting location.

C. Front Forks

1. 85-92 had smaller OD fork tubes (40mm) with air crossover tube, left side near top of fork, oil drain screw and matching triple clamps. Entire fork, triple, caliper assembly can be swapped to any year.

2. 93-07 had larger OD fork tubes (43mm)and matching triple clamps, no oil drain screw and no air balance tube, individual air valves at the top of each fork.
3. 01, slight changes fork damper rod and bolt, fork guard added to lower legs Fork Guard will not directly fit on earlier forks. The entire fork assembly must be swapped.

D. 96-07 Rear axle. Changed to 1/4" shorter axle. Washers also changed...

E. 96-07 Differential machined to accept shorter axle. Bears a surface to mount speedometer in housing. - this speedo pickup is seen on the Royal Star rear diffs (which bolts on and is 10% lower gear ratio). Would require leaving the pickup unit bolted in place. 86-93 Venture rear diffs are a direct interchange but the shock mount needs to be swapped over (or a new mount purchased and added to the Venture diff)

What Else ???

5. Electrical, Many of electrical changes in 90 due to new digital ignition

A. ECU, Upgraded to digital electronics 90..... 1985-1989=1FK-82305-09-00, 1990 on 3JP-82305-13-00..

B. VBoost controller, changed in 1993..... 1985-1992=1FK-85830-M2-00 , 1993 on 1FK-85830-M0-00.. - All years interchange.

C. Turn Signal Relay, changed in 1990.... 1985-1989=41R-83350-71-00, 1990 on 2UJ-83350-00-00...

D. Wiring Harness, changed in 90 for digital electronics... 1985-1989= 1UT-82590-01-00 , 1990 on 3JP-82590-00-00....

E. IgnitionCoils, 1985-1989=25G-82310-10-00 , the terminals are red/white and either orange, gray, yellow or white. depending on the coil/cylinder number... 1990 on, connectors are red/white and orange on the coil side of each ignition coil. Coil function and testing is the same for both. - All years interchange.

F. Reserve / normal fuel control, Fuel Pump changed in 2003. 1985-2002=1FK-13907-00-00, 2003 on 1FK-13907-01-00.. All years interchange

G. ignition Module, changed to digital in 90... 1985-1989= 1FK-82305-10-00 , 1990 on 3JP-82305-11-00....

H. Starter, Starter changed to a 4 pole model in 2001... 1985-2000= 1FK-81800-10-00, 2001 on 1FK-81890-00-00... - all years interchange.

I. Tank cover gauge cluster, changed for digital electronics 1990, 2003 different style script and redline lowered to 9,000. Instrument panel can be swapped as long as the wiring harness is the type originally used on the bike it's being installed on.

J. Speedometer: changed part number often, basic function remained the same, 2003 different style script.. 1985-1991= 3LR-83570-00-00, 1992 1FK-83570-A0-00, 1993= 1FK-83570-A1-00, 2002= 1FK-83570-A2-00, 2003 1FK-83570-B0-00, 2004=3LR-83570-00-00, 2005= 1FK-83570-B0-00, 2006-2007 5GK-83570-00-00...

K. Stator, upgraded for more output 93-07... 1985-1989= 1FK-81410-11-00, 1993 on= 3UF-81410-10-00... 86-93 Venture Stators interchange and have more output.

L. Voltage Rectifier / Regulator. Changed from original, Lower amperage. Changed to a finned model 1998-2007 model is preferred when older model goes bad or is replaced. need longer bolts for the newer model when swapping out early style regulator.

 
M. Starter Relay: Changed in 1990 to a higher resistance coil. 1985-1989, 36Y-81940-00-00, 1990 on= 3UF-81940-00-00... Wiring completely changed but it is possible to swap with a jumper wire added in on the later years.

6. Bodywork...

A. side panels VMax pressed into metal 1985. 1986 and newer have a stick on VMax badge..

B. footpegs changed style in 1986..

What Else?

Added some info. Maybe edit the first post and use what you want from above.
 
Sean, Thanx again....:biglaugh:

I edited it in with Non Bold lettering.
if I counted right, I've got 17 updates total, Very Cool..

Dave in Florida....
 
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I could post at least dozen engine casting diffrences over the years LOL

Im not sure anyone could use that:ummm:

Another hint I see is a "diode block" changed along new type ignition.
 
Thanks Prez....

:ummm: Yamaha Parts manuals don't show a change here in the states. 85 through 07 show the same part number. Are we talking the same Diodes,,, Kickstand Safety Device Diodes?
 
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At some point on newer bikes (maybe 03-up), the speedometer changed from "fives" to "tens"...as in older bikes are numbered 5, 15, 25....155, with newer ones reading 10,20,30......160. The "tens" also have a different/more modern font than the "fives", and also lost the very-eighties "red 55" mark.
 
does the fuel tank fit all gen1 models?
i have a 1991, want to know if a 2001 tank will fit
 
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