2005 YAMAHA VX110 warning

4-12
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
SERVICE POINTS
Fuel hose clamps removal
1. Remove:
Fuel hose clamps
CAUTION:
If the fuel hose clamps are removed with-
out cutting the joint first, the fuel hose will
be damaged.
Hose clamps installation
1. Install:
Fuel hose clamps
WARNING
Do not reuse the fuel hose clamps, always
replace them with new ones.
NOTE:
Crimp the fuel hose clamps properly to
securely fasten them.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the
fuel tank filler cap to reduce any pressure
inside the fuel tank, and then disconnect
the battery negative lead to cut off the elec-
tric current to the electrical systems.
1. Wrap the quick connector with a cloth, and
then rotate the quick connector tab 1
to
the stopper position a
.
WARNING
If the quick connector is removed sud-
denly, pressurized fuel could spray out. To
gradually release the fuel pressure, be sure
to remove the quick connector slowly.
1
a
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4-13
EFUEL
CAUTION:
Do not rotate the quick connector tab
1
past the stopper position, otherwise it
could be damaged.
When the fuel hoses are disconnected,
quickly remove the retainer
2 from the
quick connector, otherwise the retainer
could be lost.
2. Disconnect the fuel hose 1
from the fuel
pipe 2
directly.
WARNING
Always reduce the fuel pressure in the fuel
line before servicing the line or the fuel
pipe. If the fuel pressure is not released,
pressurized fuel could spray out.
21
1
2
3. Cover the quick connector and fuel pipe
with a plastic bag 3 to prevent damage
and to protect them from dirt.
3
Fuel line inspection
1. Inspect:
Fuel hose
Damage/cracks → Replace.
O-rings (quick connector)
Damage/cracks → Replace the quick
connector.
Fuel pipe
Damage/cracks → Replace the fuel
pump.
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
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4-16
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
Intake assembly installation
1. Install:
Intake screw clamp
Intake manifold joint
Intake assembly
NOTE:
Install the intake screw clamp in the direction
shown in the illustration, making sure to align
the indentation in the clamp with the projec-
tion a
on the intake manifold joint.
Tighten the clamp screw until both ends of
the intake screw clamp contact the spacer 1
around the screw.
a
11
2. Install:
Fuel hose 2 (fuel rail side)
Fuel hose clamps
WARNING
Do not reuse the fuel hose clamps, always
replace them with new ones.
NOTE:
Install the fuel hose with the white mark a
facing up.
Install the fuel hose clamps at the locations
shown in the illustration, and then crimp
them to securely fasten them.
2a
8 mm (0.31 in) 6 mm (0.24 in)
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5-51
EPOWRCAMSHAFTS
Install the exhaust and intake camshaft
caps.
NOTE:
Gradually tighten the intake and exhaust
camshaft cap bolts in 2–3 steps in the
sequence shown.
T R..
Camshaft cap bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
NOTE:
Make sure that the punch marks c
on the
camshafts are aligned with the arrow marks
d
on the camshaft caps.
Out of alignment →
Reinstall.
Remove the wire from the timing chain.
10 1 4 5 8
17 5 1 4 8 15 9 12 149 3 2
7 6
18 7 3 2 6
13 11 10 16
3. Install:
Timing chain tensioner
Installation steps:
While lightly pressing the timing chain
tensioner rod by hand, turn the tensioner
rod fully clockwise with a thin screwdriver
1
.
NOTE:
Make sure that the tensioner rod has been
fully set clockwise.
With the timing chain tensioner rod
turned all the way into the timing chain
tensioner housing (with the thin screw-
driver still installed), install the gasket and
the timing chain tensioner 2
onto the cyl-
inder block.
WARNING
Always use a new gasket.
Tighten the timing chain tensioner bolts
3
to the specified torque.
NOTE:
The “UP” mark on the timing chain ten-
sioner should face up.
33
2
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5-78
EPOWRCRANKCASE
5. Tighten:
Crankcase bolts 1
–0

NOTE:
Do not reuse crankcase bolts 1
–0
.
The tightening procedure of crankcase bolts
1
–0
is angle controlled, therefore tighten
the bolts using the following procedure.
Tightening steps:
Tighten the bolts in the order of the num-
bers on the crankcase.
T R..
Crankcase bolt
1–
0:
1st:
7.8 N  m
(0.78 kgf  m, 5.6 ft  lb)
Loosen and retighten the crankcase bolts
in the proper tightening sequence as
shown.
T R..
Crankcase bolt
1–
0:
2nd:
Loosen completely
3rd:
15 N  m (1.5 kgf  m, 11 ft  lb)
Tighten the crankcase bolts further to
reach the specified angle 49° in the
proper tightening sequence as shown.
T R..
Crankcase bolt
1–
0:
Final:
Specified angle 49
± 5°
WARNING
When the bolts are tightened more than
the specified angle, do not loosen the
bolt and then retighten it.
Replace the bolt with a new one and per-
form the procedure again.
15397
ICAEG
86240
HFBDJ
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5-92
EPOWRCONNECTING RODS AND PISTONS
9. Tighten:
Connecting rod nuts
WARNING
Replace the connecting rod bolts and
nuts with new ones.
Clean the connecting rod bolts and nuts.
NOTE:
The tightening procedure of the connecting rod
nuts is angle controlled, therefore tighten the
nuts using the following procedure.
Tightening steps:
Tighten the connecting rod nuts to the
specified torque.
T R..
Connecting rod nut:
1st:
20 N  m (2.0 kgf  m, 14 ft  lb)
Tighten the connecting rod nuts further to
reach the specified angle 120°.
T R..
Connecting rod nut:
Final:
Specified angle 120
± 5°
WARNING
When the nuts are tightened more than
the specified angle, do not loosen the
nut and then retighten it.
Replace the bolt and nut with a new one
and perform the procedure again.
CAUTION:
Do not use a torque wrench to tighten
the nut to the specified angle.
Tighten the nut until it is at the speci-
fied angle.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60°.
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E
–+ELEC
INDICATION SYSTEM .................................................................................. 7-48
WIRING DIAGRAM ................................................................................. 7-48
FUSE ....................................................................................................... 7-50
BATTERY ................................................................................................ 7-50
MAIN AND FUEL PUMP RELAY............................................................. 7-50
ECM......................................................................................................... 7-50
ENGINE TEMPERATURE SENSOR ...................................................... 7-50
THERMOSWITCH (ENGINE).................................................................. 7-50
THERMOSWITCH (EXHAUST) .............................................................. 7-50
REMOTE CONTROL UNIT (DELUXE MODEL ONLY) ........................... 7-50
BUZZER .................................................................................................. 7-50
OIL PRESSURE SWITCH ....................................................................... 7-51
MULTIFUNCTION METER...................................................................... 7-51
Multifunction meter ............................................................................ 7-51
MULTIFUNCTION METER REMOVAL ................................................... 7-51
Display function (Sport model only) .................................................. 7-52
Display function (Deluxe model only) ................................................ 7-53
Speedometer display ........................................................................ 7-54
Tachometer display ........................................................................... 7-55
Hour meter display ............................................................................ 7-55
Voltage meter display........................................................................ 7-55
Low oil pressure warning indicator .................................................... 7-55
Fuel level meter display and fuel warning indicator .......................... 7-55
Overheat warning indicator ............................................................... 7-56
Check engine warning indicator ........................................................ 7-56
Diagnostic display ............................................................................. 7-57
REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY) .......................... 7-58
WIRING DIAGRAM ................................................................................. 7-58
REMOTE CONTROL SYSTEM ............................................................... 7-59
Yamaha Security System indicator ................................................... 7-59
Low-rpm mode indicator.................................................................... 7-59
Checking the remote control transmitter ........................................... 7-60
Transmitter registration ..................................................................... 7-62
Replacing of the transmitter battery .................................................. 7-63
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7-14
E
–+ELECIGNITION SYSTEM
IGNITION SPARK
WARNING
When checking the spark gap, do not
touch any of the connections of the spark
checker/ignition tester lead wires.
When performing the spark gap test, take
special care not to let sparks leak out of
the removed spark plug cap.
When performing the spark gap check,
keep flammable gas or liquids away,
since this test can produce sparks.
1. Check:
Ignition spark
Weak →
Check the ECM output peak
voltage.
Check the ignition coil for resistance.
Checking steps:
Connect the spark plug cap to the special
service tool.
Spark checker:
YM-34487
Ignition tester:
90890-06754
Crank the engine and observe the igni-
tion system spark through the discharge
window.
OK
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