2005 YAMAHA VX110 Service Manual

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CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION NUMBERS ......................................................................... 1-1
PRIMARY l.D. NUMBER ........................................................................... 1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
JET PUMP UNIT SERIAL NUMBER ......................................................... 1-1
HULL IDENTIFICATION NUMBER (H.l.N.) ............................................... 1-1
SAFETY WHILE WORKING...................................................................... 1-2
FIRE PREVENTION .................................................................................. 1-2
VENTILATION ........................................................................................... 1-2
SELF-PROTECTION ................................................................................. 1-2
PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2
GOOD WORKING PRACTICES ............................................................... 1-3
DISASSEMBLY AND ASSEMBLY ............................................................ 1-4
SPECIAL SERVICE TOOLS ........................................................................... 1-5
MEASURING ............................................................................................. 1-5
REMOVAL AND INSTALLATION .............................................................. 1-7
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IDENTIFICATION NUMBERS
A60700-0*
IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label
attached to the inside of the engine compart-
ment.
Starting primary l.D. number:
F1K: 800101
ENGINE SERIAL NUMBER
The engine serial number is stamped on a
label attached to the engine unit.
Starting serial number:
6D3: 1000001
JET PUMP UNIT SERIAL NUMBER
The jet pump unit serial number is stamped on
a label attached to the intermediate housing.
HULL IDENTIFICATION NUMBER
(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.
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SAFETY WHILE WORKING
SAFETY WHILE WORKING
To prevent and accident or injury and to
ensure quality service, follow the safety proce-
dures provided below.
FIRE PREVENTION
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
VENTILATION
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled in
large quantities they may cause loss of con-
sciousness and death within a short time.
When test running an engine indoors (e.g., in a
water tank), be sure to do so where adequate
ventilation can be maintained.
SELF-PROTECTION
Protect your eyes by wearing safety glasses or
safety goggles during all operation involving
drilling and grinding, or when using an air com-
pressor.
Protect your hands and feet by wearing protec-
tive gloves or safety shoes when necessary.
PARTS, LUBRICANTS, AND
SEALANTS
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the
watercraft.
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SAFETY WHILE WORKING
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
GOOD WORKING PRACTICES
1.The right tools
Use the recommended special service
tools to protect parts from damage. Use
the right tool in the right manner—do not
improvise.
2.Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When
tightening nuts, bolts, and screws, tighten
the large sizes first, and tighten fasteners
starting in the center and moving outward.
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SAFETY WHILE WORKING
3.Non-reusable parts
Always use new gaskets, seals, O-rings,
oil seals, cotter pins, circlips, etc., when
installing or assembling parts.
DISASSEMBLY AND ASSEMBLY
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces of
moving parts during assembly.
3. Install bearings with the manufacture iden-
tification mark in the direction indication in
the installation procedure. In addition, be
sure to lubricate the bearings liberally.
4. Apply a thin coat of water-resistant grease
to the lip and periphery of an oil seal
before installation.
5. Check that moving parts operate normally
after assembly.
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SPECIAL SERVICE TOOLS
SPECIAL SERVICE TOOLS
Using the correct special service tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up. Impro-
visations and using improper tools can dam-
age the equipment.
NOTE:
For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or
“YW-”.
For other countries, use part numbers start-
ing with “90890-”.
MEASURING
1
Dial gauge stand
P/N. 90890-06583
2
Dial gauge needle
P/N. 90890-06584
3
Dial gauge stand set
P/N. YB-06585
90890-06585
4
Dial indicator gauge
P/N. YU-03097
Dial gauge set
P/N. 90890-01252
5
Pocket tester
P/N. YU-03112
90890-03112
6
Digital multimeter
P/N. YU-34899-A
7
Digital circuit tester
P/N. 90890-03174
8
Fuel pressure gauge adapter
P/N. YW-06842
90890-06842
9
Fuel pressure gauge
P/N. YB-06766
90890-06786
4 12
3
5YU-03097 90890-01252 90890-06583 90890-06584
YB-06585
90890-06585
YU-03112
90890-03112
8YW-06842
90890-06842790890-03174
6YU-34899-A
9YB-06766 90890-06786
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SPECIAL SERVICE TOOLS
0
Compression gauge extension
P/N. 90890-06582
A
Cylinder gauge set
P/N. YU-03017
90890-06759
B
Compression gauge
P/N. YU-33223-1
90890-03160
C
Peak voltage adapter
P/N. YU-39991
D
Peak voltage adapter B
P/N. 90890-03172
E
Spark checker
P/N. YM-34487
Ignition tester
P/N. 90890-06754
F
Test harness (2 pins)
P/N. New: YB-06867
Current: YB-06767
Test harness FWY-2 (2 pins)
P/N. New: 90890-06867
Current: 90890-06767
G
Test harness (3 pins)
P/N. New: YB-06870
Current: YB-06770
Test harness SMT250-3 (3 pins)
P/N. New: 90890-06870
Current: 90890-06770
H
Test harness (6 pins)
P/N. YB-06848
Test harness FSW-6A (6 pins)
P/N. 90890-06848
I
Test harness (3 pins)
P/N. New: YB-06877
Current: YB-06777
Test harness HM090-3 (3 pins)
P/N. New: 90890-06877
Current: 90890-06777
J
Lower unit pressure/vacuum tester
P/N. YB-35956-A
Vacuum/pressure pump gauge set
P/N. 90890-06756
0A
B
C
EF
GH90890-06582 YU-03017
90890-06759
YU-33223-1 90890-03160
YU-39991 90890-03172
YM-34487
90890-06754YB-06867 (-06767)
90890-06867 (-06767)
YB-06870 (-06770)
90890-06870 (-06770)YB-06848
90890-06848
D
IJYB-06877 (-06777)
90890-06877 (-06777)YB-35956-A
90890-06756
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SPECIAL SERVICE TOOLS
K
Yamaha diagnostic system
P/N. 60V-85300-02-00
L
Yamaha diagnostic system
P/N. 60V-WS853-03
L
60V-WS853-03
K60V-85300-02-00
REMOVAL AND INSTALLATION
1
Oil filter wrench
P/N. YB-01426
90890-01426
2
Coupler wrench
P/N. YW-06551
90890-06551
3
Sheave holder
P/N. YS-01880-A
90890-01701
4
Rotor puller
P/N. YM-01082
90890-01080
5
Universal magneto and rotor holder
P/N. YU-01235
Rotor holder
P/N. 90890-01235
6
Bearing housing needle bearing installer
(reduction drive gear)
P/N. YB-0611112
34YB-01426
90890-01426YW-06551
90890-06551
YS-01880-A
90890-01701YM-01082
90890-01080
56YU-01235
90890-01235YB-06111
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