2005 YAMAHA VX110 Service Manual

5-38
EPOWRGENERATOR AND STARTER MOTOR
SERVICE POINTS
Flywheel magneto removal
1. Remove:
Flywheel magneto bolt 1

Washer
NOTE:
While holding the flywheel magneto 2
with the
sheave holder 3
, loosen the flywheel magneto
bolt.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Flywheel magneto 1

Woodruff key
NOTE:
While holding the flywheel magneto with
sheave holder 2
, remove the flywheel mag-
neto with the rotor puller 3
.
Rotor puller:
YM-01082/90890-01080
Starter clutch inspection
1. Check:
Starter clutch rollers 1

Damage/wear →
Replace.
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5-39
EPOWRGENERATOR AND STARTER MOTOR
2. Check:
Starter clutch 1

Starter gear 2

Burrs/chips/roughness/wear →
Replace
the defective part(s).
3. Check:
Starter clutch gear’s contacting surfaces
a

Damage/pitting/wear →
Replace the
starter clutch gear.
12
a
4. Check:
Starter clutch operation
Checking steps:
Install the starter gear 1
onto the starter
clutch 2
and hold the starter clutch.
When turning the starter gear clockwise
È, it should turn freely, otherwise the
starter clutch is faulty and must be
replaced.
When turning the starter gear counter-
clockwise É, the starter clutch and the
starter gear should engage, otherwise
the starter clutch is faulty and must be
replaced.
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5-40
EPOWRGENERATOR AND STARTER MOTOR
Flywheel magneto installation
1. Install:
Woodruff key
Flywheel magneto
Washer
Flywheel magneto bolt
NOTE:
Clean the tapered portion of the crankshaft
and the flywheel magneto hub.
When installing the flywheel magneto, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
Lubricate the flywheel magneto bolt and
washer with engine oil.
2. Tighten:
Flywheel magneto bolt 1

NOTE:
While holding the flywheel magneto 2
with the
sheave holder 3
, tighten the flywheel mag-
neto bolt.
CAUTION:
Do not reuse the flywheel magneto bolt and
washer, always replace them with new
ones.
T R..
Flywheel magneto bolt:
75 N  m (7.5 kgf  m, 54 ft  lb)
Sheave holder:
YS-01880-A/90890-01701
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5-41
EPOWRCAMSHAFTS
CAMSHAFTS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CYLINDER HEAD COVER
REMOVALFollow the left “Step” for removal.
1Bolt 4
2 Ignition coil 4
3 Spark plug 4
4 Clamp/breather hose 1/1È
To oil tank
Paint mark a

5Bolt 1
6 Cam position sensor 1
7 Clamp/cooling water hose 1/1É
To transom plate
8 Rubber seal 1
E
4
65
7 8
10
11
12
13 9
LT
572
LT
14
16
15
3
13 N 
m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm 6 × 16 mm
2nd 7.6 N  m (0.76 kgf
 m, 5.5 ft
 Ib) 1st 3.7 N  m (0.37 kgf
 m, 2.7 ft
 Ib)
12 N 
m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É
1
2
7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 16 mm
LT
572
LTAA
1280B
1280B
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5-42
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
9Bolt 1
10 Cooling water pipe 1
11 O-ring 1
12 Bolt 6
13 Rubber mount 6
14 Cylinder head cover 1
15 Cylinder head cover gasket 1
16 Timing chain guide (top side) 1
Reverse the removal steps for installation.
E
4
65
7 8
10
11
12
13 9
LT
572
LT
14
16
15
3
13 N 
m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm 6 × 16 mm
2nd 7.6 N  m (0.76 kgf
 m, 5.5 ft
 Ib) 1st 3.7 N  m (0.37 kgf
 m, 2.7 ft
 Ib)
12 N 
m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É
1
2
7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 16 mm
LT
572
LTAA
1280B
1280B
Not reusable
Not reusable
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5-43
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CAMSHAFT REMOVAL
Follow the left “Step” for removal.
Cylinder head cover
Reduction drive gear case Refer to “REDUCTION DRIVE GEAR”.
NOTE:
When removing camshafts it is not neces-
sary to remove the reduction drive gear
case.
1 Thermoswitch (engine) coupler 1
2 Engine temperature sensor coupler 1
3 Cap bolt 1
4Gasket 1
5Bolt 2
M
E
EE
E
E
E
M
12
13
12
13
12
13
141819
10
20
10
10
15
11
16
9
17
822
21
3 4
5 6 7
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 25 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 8 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
2324
25
26
27
12
6 × 16 mm
AA
Not reusable
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5-44
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
6 Timing chain tensioner 1
7 Timing chain tensioner gasket 1
8 Timing chain guide (exhaust side) 1
9Bolt 18
10 Intake camshaft cap 3
11 Dowel pin 6
12 Bolt 10
13 Exhaust camshaft cap 3
14 Dowel pin 6
15 Intake camshaft 1
16 Bolt 2
17 Intake camshaft sprocket 1
M
E
EE
E
E
E
M
12
13
12
13
12
13
141819
10
20
10
10
15
11
16
9
17
822
21
3 4
5 6 7
10 N •
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 25 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 8 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
2324
25
26
27
12
6 × 16 mm
AA
Not reusable
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5-45
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
18 Exhaust camshaft 1
19 Bolt 2
20 Exhaust camshaft sprocket 1
21 Pin 1
22 Timing chain guide (intake side) 1
23 Bolt 1
24 Plate 1
25 Gasket 1
26 Pipe 1
27 O-ring 1
Reverse the removal steps for installation.
M
E
EE
E
E
E
M
12
13
12
13
12
13
141819
10
20
10
10
15
11
16
9
17
822
21
3 4
5 6 7
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 25 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 8 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
2324
25
26
27
12
6 × 16 mm
AA
Not reusable
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