2005 YAMAHA VX110 engine

E
HULL
HOOD
CHAPTER 8
HULL AND HOOD
HANDLEBAR .................................................................................................. 8-1
EXPLODED DIAGRAM ............................................................................. 8-1
REMOVAL AND INSTALLATION CHART ................................................ 8-1
SERVICE POINTS .................................................................................... 8-6
Handlebar inspection .......................................................................... 8-6
Handlebar switch inspection ............................................................... 8-6
Handlebar assembly installation ......................................................... 8-6
FRONT HOOD ................................................................................................. 8-8
EXPLODED DIAGRAM ............................................................................. 8-8
REMOVAL AND INSTALLATION CHART ................................................ 8-8
SERVICE POINTS .................................................................................. 8-10
Rivet Installation ................................................................................ 8-10
ENGINE HATCH COVER .............................................................................. 8-11
EXPLODED DIAGRAM ........................................................................... 8-11
REMOVAL AND INSTALLATION CHART .............................................. 8-11
SERVICE POINTS .................................................................................. 8-13
Damper stopper inspection (Deluxe model only) .............................. 8-13
EXPLODED DIAGRAM ........................................................................... 8-14
REMOVAL AND INSTALLATION CHART .............................................. 8-14
SERVICE POINTS .................................................................................. 8-15
Glove compartment assembly installation......................................... 8-15
SHIFT LEVER (DELUXE MODEL ONLY) ..................................................... 8-16
EXPLODED DIAGRAM ........................................................................... 8-16
REMOVAL AND INSTALLATION CHART .............................................. 8-16
HOSES .......................................................................................................... 8-17
EXPLODED DIAGRAM ........................................................................... 8-17
REMOVAL AND INSTALLATION CHART .............................................. 8-17
SERVICE POINTS .................................................................................. 8-19
Cooling water pilot outlet installation ................................................. 8-19
Grommet installation ......................................................................... 8-19
Ventilation hose assembly installation .............................................. 8-19
STEERING COLUMN .................................................................................... 8-20
EXPLODED DIAGRAM ........................................................................... 8-20
REMOVAL AND INSTALLATION CHART .............................................. 8-20
SERVICE POINTS .................................................................................. 8-22
Steering column inspection ............................................................... 8-22
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E
HULL
HOOD
1
2
3
4
5
6
7
8
9
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD .................... 8-23
EXPLODED DIAGRAM ........................................................................... 8-23
REMOVAL AND INSTALLATION CHART .............................................. 8-23
SERVICE POINTS .................................................................................. 8-26
Remote control cables inspection ..................................................... 8-26
Steering cable (jet pump end) installation ......................................... 8-26
Steering cable stopper installation .................................................... 8-26
Shift cable (jet pump end) installation (Deluxe model only) .............. 8-27
Shift cable (shift lever end) installation (Deluxe model only)............. 8-27
Remote control cables adjustment .................................................... 8-27
SEAT AND HAND GRIP................................................................................ 8-28
EXPLODED DIAGRAM ........................................................................... 8-28
REMOVAL AND INSTALLATION CHART .............................................. 8-28
SERVICE POINTS .................................................................................. 8-30
Seat lock assembly inspection .......................................................... 8-30
EXHAUST SYSTEM ...................................................................................... 8-31
EXPLODED DIAGRAM ........................................................................... 8-31
REMOVAL AND INSTALLATION CHART .............................................. 8-31
SERVICE POINTS .................................................................................. 8-34
Exhaust system inspection................................................................ 8-34
Exhaust component parts sub-assembly .......................................... 8-34
Exhaust system installation ............................................................... 8-35
DECK AND HULL.......................................................................................... 8-36
EXPLODED DIAGRAM ........................................................................... 8-36
REMOVAL AND INSTALLATION CHART .............................................. 8-36
ENGINE MOUNT ........................................................................................... 8-38
EXPLODED DIAGRAM ........................................................................... 8-38
REMOVAL AND INSTALLATION CHART .............................................. 8-38
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8-2
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR REMOVAL
Follow the left “Step” for removal.
1 Handlebar switch coupler 2
2 Plastic tie 1
NOTE:
Fasten the buzzer lead, steering sensor
lead, start switch lead, engine shut-off
switch lead, and multifunction meter lead
with a plastic tie.
3 Corrugated tube 1
4 Grommet 1
4 5
3
4
3
7
2
FWD
6
11
6
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8-4
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR DISASSEMBLY
Follow the left “Step” for disassembly.
1Bolt 2
2 Grip end 2
3Screw 2
NOTE:
Tighten the screw from the engine stop
switch side.
4 Handlebar switch assembly 1
5Screw 2
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8-11
E
HULL
HOODENGINE HATCH COVER
ENGINE HATCH COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ENGINE HATCH COVER
REMOVALFollow the left “Step” for removal.
1 Band 1
2 Grommet 1
3 Bolt/washer/nut 4/4/4
4Bolt 4
5 Bolt 1 Deluxe model only
6 Damper stopper 1 Deluxe model only
7 Screw 2 Deluxe model only
5
10
118 7
6
2
9
4
33
34 3
1
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)5 × 14 mm
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
5 × 16 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
3
3
3
10
7
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
4
LT
572
LT
LT
572
LT
LT
572
LT
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
572
LTFWD
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8-12
E
HULL
HOODENGINE HATCH COVER
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8 Shift lever handle 1 Deluxe model only
9 Engine hatch cover 1
10 Bolt 4
11 Multifunction meter 1
Reverse the removal steps for installation.
5
10
118 7
6
2
9
4
33
34 3
1
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)5 × 14 mm
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
5 × 16 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
3
3
3
10
7
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
4
LT
572
LT
LT
572
LT
LT
572
LT
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
572
LTFWD
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8-13
E
HULL
HOOD
SERVICE POINTS
Damper stopper inspection (Deluxe model
only)
1. Install:
Damper stopper 1

Shift lever handle 2

NOTE:
To install the damper stopper, insert it into the
hole in the shift lever handle from the bottom,
and then slide it upward.
2
1
ENGINE HATCH COVER
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8-14
E
HULL
HOODENGINE HATCH COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
GLOVE COMPARTMENT
REMOVAL Follow the left “Step” for removal.
1 Hinge assembly 2
2Lid 1
3 Latch 1
4 Cap holder 1
5 Hood bumper 2
6Drain plug 1
Reverse the removal steps for installation.
4 3
2
1
5
56
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