2005 YAMAHA VX110 Service Manual

5-30
EPOWRREDUCTION DRIVE GEAR
Bearing installing
1. Install:
Reduction drive gear bearing
NOTE:
Install the reduction driver gear bearing using
a press.
Driver handle—large:
YB-06071
Driver rod LS:
90890-06606
Outer race installer—forward
gear:
YB-06085
Ball bearing attachment:
90890-06631
2. Install:
Front bearing
NOTE:
Install the front bearing using a press.
ÈFor USA and Canada
ÉFor worldwide
Driver rod LS:
90890-06606
Forward gear bearing cup
installer:
YB-06276-B
Ball bearing attachment:
90890-06657
È
É
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5-31
EPOWRREDUCTION DRIVE GEAR
3. Install:
Collar
Rear bearing
NOTE:
Install the front bearing using a press.
Before installing the rear bearing, hold both
the inner and outer races of the front bearing
in place as shown with a pipe that is at least
40 mm (1.57 in) long and has an outer diam-
eter of 70 mm (2.76 in) and an inner diame-
ter of 30 mm (1.18 in).
ÈFor USA and Canada
ÉFor worldwide
Driver rod LS:
90890-06606
Outer race installer—forward
gear:
YB-06085
Bearing outer race attachment:
90890-06624
È
É
4. Install:
Oil seals
ÈFor USA and Canada
ÉFor worldwide
Driver handle—large:
YB-06071
Driver rod LS:
90890-06606
Outer race installer—forward
gear:
YB-06085
Bearing outer race attachment:
90890-06624
Distance
a:
17.9
± 0.2 mm (0.70
± 0.01 in)
Distance
b:
9.3
± 0.2 mm (0.37
± 0.01 in)
ab
È
ab
É
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5-32
EPOWRREDUCTION DRIVE GEAR
Drive shaft installation
1. Install:
Drive shaft
Collar
NOTE:
Press the into the reduction drive gear case
using a pipe that is more than 30 mm (1.18 in)
long, and which has an outer diameter of
approximately 35 mm (1.97 in) and an inner
diameter of approximately 28 ±
0.5 mm (1.10 ±
0.02 in).
Drive coupling installation
1. Install:
Drive coupling 1

NOTE:
While holding the drive shaft 2
with the rotor
holder 3
, tighten the drive coupling with the
coupler wrench 4
.
2. Install:
Reduction drive gear housing
Coupler wrench:
YW-06551/90890-06551
Universal magneto and rotor
holder:
YU-01235
Rotor holder:
90890-01235
T R..
Drive coupling:
28 N  m (2.8 kgf  m, 20 ft  lb)
LOCTITE 572
1
4
23
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5-33
EPOWRGENERATOR AND STARTER MOTOR
GENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
GENERATOR COVER AND
FLYWHEEL MAGNETO
REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
1 Nut/washer 1/1
2 Starter motor lead 1
3Bolt 2
4 Battery negative lead 1
5 Starter motor 1
6 Band 1
7 Lighting coil coupler 1
4 3
2 1
5
7
89
1113 12
18 16171920 21
15 14
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf
 m, 13 ft
 Ib)
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf
 m, 54 ft
 Ib) 8 × 20 mm
24 N  m (2.4 kgf
 m, 17 ft
 Ib)
10 × 60 mm
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
6
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
10 × 135 mm
10
LT
572
LT
572
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5-34
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8 Pickup coil coupler 1
9Bolt 6
10 Bolt 2
11 Generator cover 1
12 Dowel pin 2
13 Gasket 1
14 Idle gear shaft 1
15 Idle gear 1
16 Bolt/washer 1/1
17 Flywheel magneto 1
18 Bolt 6
4 3
2 1
5
7
89
1113 12
18 16171920 21
15 14
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf
 m, 13 ft
 Ib)
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf
 m, 54 ft
 Ib) 8 × 20 mm
24 N  m (2.4 kgf
 m, 17 ft
 Ib)
10 × 60 mm
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
6
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
10 × 135 mm
10
LT
572
LT
572
Not reusable
Not reusable
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5-35
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
19 Starter clutch 1
20 Starter gear 1
21 Woodruff key 1
Reverse the removal steps for installation.
4 3
2 1
5
7
89
1113 12
18 16171920 21
15 14
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf
 m, 13 ft
 Ib)
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf
 m, 54 ft
 Ib) 8 × 20 mm
24 N  m (2.4 kgf
 m, 17 ft
 Ib)
10 × 60 mm
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
6
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
10 × 135 mm
10
LT
572
LT
572
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5-36
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
GENERATOR DISASSEMBLY
Follow the left “Step” for disassembly.
1 Bolt/washer 1/1
2Bolt 2
3 Pickup coil 1
NOTE:
There washer hold the pickup coil lead.
Make sure to not pitch the lead between the
projection and the washer when installing
the bolt.
4Bolt 2
1
7
6
3
2
45
LT
242
LT
242
LT
242LT
242
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 14 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 14 mm
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 35 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 10 mm
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5-37
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
5 Holder 1
6Bolt 3
7 Lighting coil 1
Reverse the disassembly steps for
assembly.
1
7
6
3
2
45
LT
242
LT
242
LT
242LT
242
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 14 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 14 mm
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 35 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 10 mm
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