2005 YAMAHA VX110 Service Manual

3-24
E
INSP
ADJ
ELECTRICAL
3. Inspect:
Specific gravity
Out of specification →
Charge.
4. Install:
Filler caps
CAUTION:
Before installation, rinse off any fluid from
the battery box and battery and make sure
that the battery is dry before installing it.
Specific gravity at 20 °C (68 °F):
1.28
Charging current:
1.9 A
× 10 h
5. Install:
Battery breather hose 1

Battery
Battery positive lead 2

Battery negative lead 3

Bands
CAUTION:
Connect the positive lead to the battery
terminal first.
Make sure the battery leads are con-
nected properly. Reversing the leads can
seriously damage the electrical system.
Make sure that the battery breather hose is
properly connected and is not obstructed.
Coat the terminals with a water resistant
grease to minimize terminal corrosion.
ProCarManuals.com

3-25
E
INSP
ADJ
JET PUMP UNIT
JET PUMP UNIT
Impeller inspection
1. Check:
Impeller 1

Damage/wear →
Replace.
Nicks/scratches →
File or grind.
2. Measure:
Impeller-to-housing clearancea

Out of specification →
Replace.
Maximum impeller-to-housing
clearance:
0.35–0.45 mm (0.0138–0.0177 in)
Measurement steps:
Remove the battery leads.
Remove the intake grate and intake duct.
Refer to “INTAKE GRATE AND RIDE
PLATE” in Chapter 6.
Measure the clearance at each impeller
blade as shown (a total of three measure-
ments).
Install the intake duct and intake grate.
Refer to “INTAKE GRATE AND RIDE
PLATE” in Chapter 6.
Install the battery leads.
Water inlet strainer inspection
1. Inspect:
Water inlet strainer
Contaminants →
Clean.
Cracks/damage →
Replace.
Inspection steps:
Remove the ride plate.
Refer to “INTAKE GRATE AND RIDE
PLATE” in Chapter 6.
Remove the rubber plate.
Refer to “JET PUMP UNIT” in Chapter 6.
Remove the water inlet cover 1
.
Inspect the water inlet strainer mesh a
.
Install the water inlet cover.
Install the rubber plate.
Refer to “JET PUMP UNIT” in Chapter 6.
Install the ride plate.
Refer to “INTAKE GRATE AND RIDE
PLATE” in Chapter 6.
a
1
ProCarManuals.com

3-26
E
INSP
ADJ
BILGE PUMP/GENERAL
BILGE PUMP
Bilge strainer inspection
1. Inspect:
Bilge strainer 1

Contaminants →
Clean.
Cracks/damage →
Replace.
1
GENERAL
Drain plug inspection
1. Inspect:
Drain plugs
Cracks/damage →
Replace.
O-rings
Cracks/wear →
Replace.
Screw threads
Contaminants →
Clean.
Lubrication points
1. Lubricate:
Throttle cable (handlebar end)
NOTE:
Before lubricating the throttle cable, squeeze
the throttle lever and remove the rubber seal
1
.
Recommended lubricant:
Rust inhibitor
ProCarManuals.com

3-27
E
INSP
ADJ
GENERAL
2. Lubricate:
Nozzle pivot shaft
Steering cable (nozzle end)
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
3. Lubricate:
Steering cable
Steering cable joint
NOTE:
Disconnect the joints and apply a small
amount of grease.
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
4. Lubricate: (Deluxe model only)
Shift cable (shift lever end)
Shift cable (reverse gate end)
Shift cable joint
NOTE:
Disconnect the joints and apply a small
amount of grease.
Recommended grease:
Yamaha marine grease,
Yamaha grease A
(Water resistant grease)
ProCarManuals.com

EFUEL
1
2
3
4
5
6
7
8
9
CHAPTER 4
FUEL SYSTEM
FUEL TANK AND FUEL PUMP MODULE...................................................... 4-1
EXPLODED DIAGRAM ............................................................................. 4-1
REMOVAL AND INSTALLATION CHART ................................................ 4-1
SERVICE POINTS .................................................................................... 4-4
Fuel hose disconnection ..................................................................... 4-4
Fuel pump module removal................................................................. 4-4
Check valve inspection ....................................................................... 4-4
Fuel sender inspection ........................................................................ 4-5
Fuel tank inspection ............................................................................ 4-5
Fuel hose inspection ........................................................................... 4-5
Fuel pump filter inspection .................................................................. 4-5
Fuel pump module installation ............................................................ 4-6
Fuel hose connect ............................................................................... 4-6
FUEL INJECTION SYSTEM ............................................................................ 4-7
EXPLODED DIAGRAM ............................................................................. 4-7
REMOVAL AND INSTALLATION CHART ................................................ 4-7
THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD ........................ 4-10
EXPLODED DIAGRAM ........................................................................... 4-10
REMOVAL AND INSTALLATION CHART .............................................. 4-10
SERVICE POINTS .................................................................................. 4-12
Fuel hose clamps removal ................................................................ 4-12
Hose clamps installation ................................................................... 4-12
Fuel hose disconnection ................................................................... 4-12
Fuel line inspection ........................................................................... 4-13
Fuel hose installation (replacing with new fuel hose) ........................ 4-14
Fuel hose connection ........................................................................ 4-14
Fuel injectors inspection.................................................................... 4-15
Throttle body assembly inspection .................................................... 4-15
Accelerator position sensor inspection.............................................. 4-15
Intake assembly installation .............................................................. 4-16
Air filter case assembly installation ................................................... 4-17
Fuel pressure measurement ............................................................. 4-17
ProCarManuals.com

4-1
EFUELFUEL TANK AND FUEL PUMP MODULE
FUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL TANK REMOVAL
Follow the left “Step” for removal.
Storage compartment panel Refer to “FRONT HOOD” in Chapter 8.
Ventilation hose From ventilation fitting
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
NOTE:
When removing the pump module only, it is
not necessary to remove the engine unit.
1 Fuel tank breather hose 1
2 Check valve 1
NOTE:
Make sure the arrow direction pointed
toward fuel tank.
7
10
11 3
2
1
18
17121315
16
14
12 6 5
4 8
9
2nd 6.4 N • m (0.64 kgf  m, 4.6 ft  Ib) 1st 3.2 N  m (0.32 kgf  m, 2.3 ft  Ib)
3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
5.9 N  m (0.59 kgf  m, 4.3 ft  Ib)
ProCarManuals.com

4-2
EFUELFUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
3 Fuel tank breather hose 1
NOTE:
Make sure that the inner seal of the coupler
is installed properly before connecting the
coupler. 4 Fuel sender coupler 1
5 Fuel pump module coupler 1
6 Cover 1
7 Fuel hose 1
8Nut 9
9 Retainer 1
10 Fuel pump module 1
11 Packing 1
7
10
11 3
2
1
18
17121315
16
14
12 6 5
4 8
9
2nd 6.4 N  m (0.64 kgf  m, 4.6 ft  Ib) 1st 3.2 N  m (0.32 kgf  m, 2.3 ft  Ib)
3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
5.9 N  m (0.59 kgf  m, 4.3 ft  Ib)
ProCarManuals.com

4-3
EFUELFUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
12 Hose clamp 2
13 Fuel filler hose 1
14 Nut 1
15 Fuel filler neck 1
16 Rubber seal 1
17 Fuel tank belt 2
18 Fuel tank assembly 1
Reverse the removal steps for installation.
7
10
11 3
2
1
18
17121315
16
14
12 6 5
4 8
9
2nd 6.4 N  m (0.64 kgf  m, 4.6 ft  Ib) 1st 3.2 N  m (0.32 kgf  m, 2.3 ft  Ib)
3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
5.9 N  m (0.59 kgf  m, 4.3 ft  Ib)
ProCarManuals.com