2005 YAMAHA VX110 service

1-5
E
GEN
INFO
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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1-6
E
GEN
INFO
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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1-7
E
GEN
INFO
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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1-8
E
GEN
INFO
SPECIAL SERVICE TOOLS
7
Forward gear bearing cup installer
(reduction drive gear)
P/N. YB-06276-B
8
Ball bearing attachment
(reduction drive gear)
P/N. 90890-06657
9
Valve spring compressor
P/N. YM-01253
90890-04019
0
Valve spring compressor attachment
P/N. YM-04114 (ø19 mm)
90890-04114 (ø19 mm)
YM-04108 (ø22 mm)
90890-04108 (ø22 mm)
A
Valve guide remover
P/N. YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
B
Valve guide installer
P/N. YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
C
Valve guide reamer
P/N. YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
D
Valve seat cutter
Intake
P/N. 90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
Exhaust
P/N. 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
0
AYM-04114 (ø19 mm)
90890-04114 (ø19 mm)
YM-04108 (ø22 mm)
90890-04108 (ø22 mm)
YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
7YB-06276-B8
990890-06657
YM-01253
90890-04019
B
CYM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
D90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
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1-9
E
GEN
INFO
SPECIAL SERVICE TOOLS
E
Valve seat cutter holder
P/N. 90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
F
Neway valve seat cutter kit
P/N. YM-91044
G
Piston ring compressor
P/N. YM-08037
90890-05158
H
Drive shaft holder (impeller)
P/N. YB-06151
Drive shaft holder 5 (impeller)
P/N. 90890-06519
I
Slide hammer and adapters
(jet pump bearing and reduction drive
gear)
P/N. YB-06096
J
Stopper guide plate (jet pump bearing)
P/N. 90890-06501
K
Bearing puller assembly
(jet pump bearing and reduction drive
gear)
P/N. 90890-06535
L
Stopper guide stand
(jet pump bearing and reduction drive
gear)
P/N. 90890-06538
M
Driver rod L3
(jet pump bearing and reduction drive
gear)
P/N. 90890-06652
N
Bearing housing needle bearing remover
(jet pump bearing)
P/N. YB-06112
O
Needle bearing attachment
(jet pump bearing, oil seal, and reduction
drive gear)
P/N. 90890-06614, 90890-06653
Ball bearing attachment
(jet pump oil seal)
P/N. 90890-06634
YM-08037 90890-05158
YB-06096
90890-06501 90890-06535
E
G
HI
JK90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
YB-06151
90890-06519YM-91044F
90890-06538 90890-06652LM
YB-06112 90890-06614NO90890-06653
90890-06634
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1-10
E
GEN
INFO
SPECIAL SERVICE TOOLS
P
Outer race installer—forward gear
(jet pump oil seal and reduction drive gear)
P/N. YB-06085
Q
Ball bearing attachment
(jet pump oil seal and reduction drive gear)
P/N. 90890-06631
R
Driver handle—large
(intermediate shaft, jet pump, and
reduction drive gear)
P/N. YB-06071
S
Driver rod LS
(intermediate shaft, jet pump, and
reduction drive gear)
P/N. 90890-06606
T
Crankshaft holder (intermediate shaft)
P/N. YB-06552
Crankshaft holder 20 (intermediate shaft)
P/N. 90890-06552
U
Bearing outer race attachment
(intermediate shaft and reduction drive
gear)
P/N. 90890-06624, 90890-06628
V
Roller bearing installer/remover
(intermediate shaft bearing and oil seals)
P/N. YB-06432
YB-06071 90890-06606 RS
YB-06552
90890-06552T
YB-06085 P90890-06631Q
90890-06624 YB-06156U90890-06626
YB-06432V
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E
INSP
ADJ
1
2
3
4
5
6
7
8
9
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART .............................................................. 3-1
PERIODIC SERVICE ....................................................................................... 3-2
CONTROL SYSTEM ................................................................................. 3-2
Steering column inspection ................................................................. 3-2
Steering cable inspection and adjustment .......................................... 3-2
Throttle cable inspection and adjustment............................................ 3-4
Shift cable inspection and adjustment (Deluxe model only)................ 3-5
Trolling speed inspection .................................................................... 3-6
FUEL SYSTEM.......................................................................................... 3-7
Fuel line inspection ............................................................................. 3-7
Water separator inspection ................................................................. 3-8
POWER UNIT............................................................................................ 3-8
Valve clearance adjustment ................................................................ 3-8
Engine oil level check........................................................................ 3-14
Engine oil change — using oil changer ............................................. 3-16
Air filter element clean....................................................................... 3-18
Spark plug inspection ........................................................................ 3-20
ELECTRICAL .......................................................................................... 3-22
Battery inspection.............................................................................. 3-22
JET PUMP UNIT ..................................................................................... 3-25
Impeller inspection ............................................................................ 3-25
Water inlet strainer inspection ........................................................... 3-25
BILGE PUMP........................................................................................... 3-26
Bilge strainer inspection .................................................................... 3-26
GENERAL ............................................................................................... 3-26
Drain plug inspection......................................................................... 3-26
Lubrication points .............................................................................. 3-26
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3-2
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INSP
ADJ
CONTROL SYSTEM
PERIODIC SERVICE
CONTROL SYSTEM
Steering column inspection
1. Inspect:
Steering column
Excessive play →
Replace the steering
column.
Refer to “STEERING COLUMN” in
Chapter 8.
Inspection steps:
Move the handlebar up and down and
back and forth.
Check the excessive play of the handle-
bar.
Steering cable inspection and adjustment
1. Inspect:
Jet thrust nozzle distances a
and b

Out of specification →
Adjust.
Difference of distances
a and
b:
Maximum 5 mm (0.2 in)
Measurement steps:
Set the control grip to the neutral posi-
tion.
Turn the handlebar lock to lock.
Measure distances a
and b
.
If the difference of distances a
and b
is
not within specification, adjust the cable
joint.
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