2005 YAMAHA VX110 Service Manual

8-4
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR DISASSEMBLY
Follow the left “Step” for disassembly.
1Bolt 2
2 Grip end 2
3Screw 2
NOTE:
Tighten the screw from the engine stop
switch side.
4 Handlebar switch assembly 1
5Screw 2
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8-5
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
6 Throttle lever assembly 1
7 Handlebar grip 2
NOTE:
Apply adhesive to the handlebar and the
inner surface of the handlebar grip.
8 End plate 2
9 Handlebar 1
Reverse the disassembly steps for
assembly.
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8-6
E
HULL
HOODHANDLEBAR
SERVICE POINTS
Handlebar inspection
1. Inspect:
Handlebar
Bends/cracks/damage →
Replace.
Handlebar switch inspection
Refer to “STARTING SYSTEM” in
Chapter 7.
Handlebar assembly installation
1. Install:
Handlebar switch lead 1

NOTE:
Be sure to leave some slack in the handlebar
switch lead 1
in the area a
shown in the illus-
tration.
2. Install:
Upper handlebar holder 1

NOTE:
The upper handlebar holder should be installed
with the punch mark a
facing forward.
CAUTION:
Clearance
b should be narrower than
clearance
c.
T R..
Handlebar holder bolt:
20 N  m (2.0 kgf  m, 14 ft  lb)
LOCTITE 572
Reference clearance:
b: 1.5 mm (0.06 in)
c: 3.5 mm (0.14 in)
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8-7
E
HULL
HOODHANDLEBAR
3. Install:
Throttle cable
NOTE:
Fit the seal into the groove in the bracket.
4. Install:
Pad 1

NOTE:
Make sure that the handlebar switch lead 2
and throttle cable 3
are routed behind the pad
1
when installing the pad 1
onto the steering
column.
5. Adjust:
Throttle cable free play
Refer to “CONTROL SYSTEM” in Chap-
ter 3.
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8-8
E
HULL
HOODFRONT HOOD
FRONT HOOD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FRONT HOOD REMOVAL
Follow the left “Step” for removal.
1 Bolt/washer/nut 2/2/2
2 Front hood assembly 1
3Bolt 2
4 Hood lock assembly 1
5 Hinge assembly 1
6Bolt 4
7 Nut/washer 4/4 Deluxe model only
8 Left mirror/seal 1/1 Deluxe model only
4
31011
13
8 7 1
9
52
12
6
5 × 20 mm
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
6 × 18 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
242
LT
6 × 18 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)LT
242
LT
15 N • m (1.5 kgf • m, 11 ft • Ib)
LT
572
LT
6 × 95 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
1
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8-9
E
HULL
HOODFRONT HOOD
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
9 Right mirror/seal 1/1 Deluxe model only
10 Rivet 4
11 Storage compartment panel 1
12 Bolt 2
13 Lid lock hook 1
Reverse the removal steps for installation.
4
31011
13
8 7 1
9
52
12
6
5 × 20 mm
1.9 N • m (0.19 kgf • m, 1.4 ft • Ib)
6 × 18 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
242
LT
6 × 18 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)LT
242
LT
15 N • m (1.5 kgf • m, 11 ft • Ib)
LT
572
LT
6 × 95 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
1
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8-10
E
HULL
HOODFRONT HOOD
SERVICE POINTS
Rivet Installation
1. Install:
Rivets
Installing steps:
Insert a rivet completely in the holes in
both the storage compartment panel 1
and inner hull.
Push in the rivet pin 2
until it clicks and
is flush with the top of the rivet.
NOTE:
To remove a rivet, push the rivet pin in
until it clicks and is below the top of the
rivet.
Before reinstalling a rivet, hold the rivet
flange a
with both hands and push the
rivet pin perpendicularly against a hard
flat surface until the pin protrudes from the
top of the rivet.
2
1
a
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8-11
E
HULL
HOODENGINE HATCH COVER
ENGINE HATCH COVER
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ENGINE HATCH COVER
REMOVALFollow the left “Step” for removal.
1 Band 1
2 Grommet 1
3 Bolt/washer/nut 4/4/4
4Bolt 4
5 Bolt 1 Deluxe model only
6 Damper stopper 1 Deluxe model only
7 Screw 2 Deluxe model only
5
10
118 7
6
2
9
4
33
34 3
1
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)5 × 14 mm
3.9 N • m (0.39 kgf • m, 2.8 ft • Ib)
5 × 16 mm
3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)
3
3
3
10
7
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
4
LT
572
LT
LT
572
LT
LT
572
LT
6 × 23 mm
6.9 N • m (0.69 kgf • m, 5.0 ft • Ib)
LT
572
LTFWD
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