2005 YAMAHA VX110 service

7-39
E
–+ELECSTARTER MOTOR
STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
STARTER MOTOR
DISASSEMBLYFollow the left “Step” for disassembly.
Starter motor Refer to “GENERATOR AND STARTER
MOTOR” in Chapter 5.
1 O-ring 1
2Bolt 2
3 Starter motor front cover assembly 1
4 O-ring 2
5 Washer set 1
6 Armature assembly 1
AA
5 × 114 mm
6.4 N  m (0.64 kgf  m, 4.6 ft  Ib)5
72
9
44 6
5
3
1
8
8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
Not reusable
Not reusable
ProCarManuals.com

7-40
E
–+ELECSTARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
7 Starter motor rear cover 1
8 Brush holder assembly 1
9 Starter motor yoke 1
Reverse the disassembly steps for
assembly.
AA
5 × 114 mm
6.4 N  m (0.64 kgf  m, 4.6 ft  Ib)5
72
9
44 6
5
3
1
8
8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
ProCarManuals.com

7-41
E
–+ELECSTARTER MOTOR
SERVICE POINTS
Armature inspection
1. Inspect:
Armature shaft 1
Damage/wear → Replace.
1
2. Inspect:
Commutator
Dirt → Clean with 600-grit sandpaper.
3. Measure:
Commutator diameter
Below specification → Replace.
Commutator diameter:
28.0 mm (1.10 in)
Limit:
27.0 mm (1.06 in)
4. Check:
Commutator undercut
Contaminants → Clean.
NOTE:
Remove all mica and metal particles with com-
pressed air.
5. Measure:
Commutator undercut
Below specification → Replace.
Commutator undercut:
0.7 mm (0.03 in)
Limit:
0.2 mm (0.01 in)
ProCarManuals.com

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
ProCarManuals.com

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
ProCarManuals.com

8-1
E
HULL
HOODHANDLEBAR
HANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR REMOVAL
Follow the left “Step” for removal.
1Screw 4
2Screw 4
3Screw 2
4 Upper handlebar cover 1
5Pad 1
6 Throttle cable 1
7Bolt 4
8 Upper handlebar holder 2
9 Handlebar assembly 1
10 Lower handlebar cover 1
Reverse the removal steps for installation.
LT
242
8 × 48 mm
20 N • m (2.0 kgf
• m, 14 ft
• Ib)
6 × 13 mm
3.7 N • m (0.37 kgf
• m, 2.7 ft
• Ib)
4 × 9 mm
1.1 N • m (0.11 kgf
• m, 0.8 ft
• Ib)
5 × 15 mm
1.1 N • m (0.11 kgf
• m, 0.8 ft
• Ib)
87
1
2
910
5
4
3
6
FWD
AA
LT
572
ProCarManuals.com

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
ProCarManuals.com

8-3
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
5 Throttle cable 1
NOTE:
Pass the throttle cable and wiring harness
through the grommet, and then fit the grom-
met into the steering column.
6 Handlebar switch lead 1
7 Handlebar assembly 1
Reverse the removal steps for installation.
4 5
3
4
3
7
2
FWD
6
11
6
ProCarManuals.com