2005 YAMAHA VX110 Service Manual

7-38
E
–+ELECSTARTING SYSTEM
STARTER RELAY
1. Inspect:
Brown lead terminal
Black lead terminal
Loose →
Tighten.
2. Check:
Starter relay
Faulty →
Replace.
Checking steps:
Connect the tester leads between the
starter relay terminals as shown.
Connect the brown lead terminal to the
positive battery terminal.
Connect the black lead terminal to the
negative battery terminal.
Check that there is continuity between
the starter relay terminals.
Check that there is no continuity after the
brown or black lead is removed.
Br
B
REMOTE CONTROL UNIT
(DELUXE MODEL ONLY)
Refer to “REMOTE CONTROL SYS-
TEM (DELUXE MODEL ONLY)”.
THROTTLE POSITION SENSOR
Refer to “IGNITION SYSTEM”.
ACCELERATOR POSITION SENSOR
Refer to “IGNITION SYSTEM”.
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7-39
E
–+ELECSTARTER MOTOR
STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
STARTER MOTOR
DISASSEMBLYFollow the left “Step” for disassembly.
Starter motor Refer to “GENERATOR AND STARTER
MOTOR” in Chapter 5.
1 O-ring 1
2Bolt 2
3 Starter motor front cover assembly 1
4 O-ring 2
5 Washer set 1
6 Armature assembly 1
AA
5 × 114 mm
6.4 N  m (0.64 kgf  m, 4.6 ft  Ib)5
72
9
44 6
5
3
1
8
8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
Not reusable
Not reusable
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7-40
E
–+ELECSTARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
7 Starter motor rear cover 1
8 Brush holder assembly 1
9 Starter motor yoke 1
Reverse the disassembly steps for
assembly.
AA
5 × 114 mm
6.4 N  m (0.64 kgf  m, 4.6 ft  Ib)5
72
9
44 6
5
3
1
8
8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
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7-41
E
–+ELECSTARTER MOTOR
SERVICE POINTS
Armature inspection
1. Inspect:
Armature shaft 1
Damage/wear → Replace.
1
2. Inspect:
Commutator
Dirt → Clean with 600-grit sandpaper.
3. Measure:
Commutator diameter
Below specification → Replace.
Commutator diameter:
28.0 mm (1.10 in)
Limit:
27.0 mm (1.06 in)
4. Check:
Commutator undercut
Contaminants → Clean.
NOTE:
Remove all mica and metal particles with com-
pressed air.
5. Measure:
Commutator undercut
Below specification → Replace.
Commutator undercut:
0.7 mm (0.03 in)
Limit:
0.2 mm (0.01 in)
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7-42
E
–+ELECSTARTER MOTOR
6. Inspect:
Armature coil continuity
Out of specification → Replace.
Armature coil continuity:
Commutator segments 1 Continuity
Segment - Laminations 2 No continuity
Segment - Armature shaft No continuity
Brush holder inspection
1. Measure:
Brush length a
Below specification → Replace.
Brush length:
12.5 mm (0.49 in)
Wear limit:
6.5 mm (0.26 in)
2. Check:
Brush holder continuity
Out of specification → Replace.
Brush holder continuity:
Brush holder - Base No continuity
Starter motor front cover inspection
1. Inspect:
Starter motor front cover oil seal
Damage/wear → Replace the starter
motor front cover.
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7-43
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–+ELECCHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM
10A
10A
3A
30A20A
RR
BBRGGGGGG
RGGGB
R
B
4 5
32 1
1Battery
2Fuse (30 A)
3Fuse (20 A)
4Rectifier/regulator
5Lighting coilB: Black
G : Green
R: Red
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7-44
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–+ELECCHARGING SYSTEM
FUSE
Refer to “STARTING SYSTEM”.
BATTERY
Refer to “ELECTRICAL” in Chapter 3.
LIGHTING COIL
Refer to “IGNITION SYSTEM”.
RECTIFIER/REGULATOR
Refer to “IGNITION SYSTEM”.
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7-45
E
–+ELECOFF THROTTLE STEERING SYSTEM
OFF THROTTLE STEERING SYSTEM
WIRING DIAGRAM
10A
10A
3A
30A20A
RR
BBR
B/W
B/O
B/O
B/O
B/R
P/R
P/R
B/O
W/B
P/W
P/W
B/WB/R
B/O
P/RP/W
G
O
O
W
BW
O
OLG
W
W/BR/Y
W/LY/G
R/Y
BL
BPu/RPu/B
Pu/GPu/Y
R/Y
Y/WL/R
R/Y
R/Y
R/Y
R/YPu/G
Pu/Y
Pu/B
Pu/RR/Y
R/Y
R/Y
R/YY/W
Y/G
L/R
R
R
R
B
W/LBOW/LB/OO
R
98
0
0 0 0 ABC D E1
4
5
67 32
1Battery
2Starter motor
3Fuse (30 A)
4Fuse (20 A)
5Fuse (10 A)
6Fuse (10 A)
7Starter relay
8Main and fuel pump relay
9Electronic control throttle valve relay0Fuel injector
AECM
BThrottle body assembly
CAccelerator position sensor
DPickup coil
ESteering sensor
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